Engine for generating control plans for digital pre-print paper, sheet, and box manufacturing systems

ABSTRACT

Systems for providing efficient manufacturing of paper, sheet, and/or box products of varying size and structure, often with pre-applied print (“pre-print”), are provided herein. One or more controllers can be used to aggregate upcoming orders and information needed to complete the manufacturing process for the order. A controller enables a user to prepare control plans (e.g., reel maps, reel plans, etc.) for processing rolls of web product through the manufacturing process. Criteria filtering and/or various features enable generation of efficient and effective control plans for rolls of web product, including, in some cases, multiple orders. The control plan may include a set of instructions for operating one or more systems within the manufacturing process to form the desired finished paper-based product. In such a regard, efficient manufacturing of various paper-based products, including corrugated boxes, folded carton, labels, flexible paper, industrial bags, plates, cups, décor, and many others, can be achieved.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/649,942, entitled “Engine for Generating Control Plans forDigital Pre-Print Paper, Sheet, and Box Manufacturing Systems”, filedMar. 29, 2018; U.S. Provisional Patent Application No. 62/619,998,entitled “Engine for Generating Control Plans for Digital Pre-PrintPaper, Sheet, and Box Manufacturing Systems”, filed Jan. 22, 2018; U.S.Provisional Patent Application No. 62/597,079, entitled “Engine forGenerating Control Plans for Digital Pre-Print Paper, Sheet, and BoxManufacturing Systems”, filed Dec. 11, 2017; U.S. Provisional PatentApplication No. 62/583,845, entitled “Engine for Creating Orders forDigital Pre-Print, Sheet, and Box Manufacturing Systems”, filed Nov. 9,2017; and U.S. Provisional Patent Application No. 62/532,483, entitled“Digital Pre-Print Paper, Sheet, and Box Manufacturing Systems”, filedJul. 14, 2017, each of which is hereby incorporated by reference in itsentirety.

FIELD OF THE INVENTION

Example embodiments of the present invention generally relate to paper,sheet and box manufacturing systems and, more particularly, togenerating control plans for digital pre-print paper, sheet and boxmanufacturing systems.

BACKGROUND

Paper, sheet, and/or box manufacturing systems include many differentsystems and/or phases to form a finished paper-based product. Some suchmanufacturing may utilize print systems that print one or more images(e.g., symbols, marketing indicia, product information, etc.) on theproduct. For example, a roll of web product may pass through a printingpress and receive one or more images. Such printing may occur aftersheet formation/processing (e.g., after forming a layered corrugate),often being called “post-print”. Alternatively, such printing may occurprior to sheet formation/processing (e.g., on a top layer prior toformation of the layered corrugate), often being called “pre-print”.Once printed on, the roll of web product can pass through various sheetformation/processing and/or finishing systems to ultimately form thefinished paper-based product.

BRIEF SUMMARY

Embodiments of the present invention provide systems for generatingcontrol plans for rolls of web product that are used to controlmanufacturing processes for paper-based products. While some of thedescription herein of example embodiments focuses on corrugated boxmanufacturing, some embodiments of the present invention arecontemplated for extension into other product manufacturing, includingother paper-based product manufacturing, such as folded carton,beverage, labels, flexible paper, industrial bags, plates, cups, décor,and many others.

Some embodiments of the present invention contemplate a designedplatform with various modules that can be used throughout themanufacturing process. For example, one or more controllers can be usedto aggregate orders and information to prepare one or more control plans(e.g., reel maps, reel plans, etc.) for processing a roll of web productthrough the manufacturing process. The control plan may include a set ofinstructions for operating one or more systems within the manufacturingprocess to ultimately form the desired finished paper-based product. Insuch a regard, some embodiments contemplate one or more controllers thatcan generate and provide a control plan to various devices/systems forperforming efficient manufacturing of paper-based products, includingcorrugated boxes, folded carton, labels, flexible paper, industrialbags, plates, cups, décor, and many others.

In some embodiments, a controller may allow a user to generate a controlplan based on available orders. Criteria, such as upcoming deadlines,customers, paper type, paper width, planned/available manufacturingsystems, location of manufacturing systems, ink type, color profiles,etc., may be used to filter the available orders. In some embodiments,such criteria may be used to provide suggestions or recommendations forgeneration of the control plan. Multiple orders can be added to acontrol plan and certain functions/features can be provided to reduceunnecessary waste. Along these lines, some features may prevent orhighlight improper or inefficient combinations of orders and may, insome cases, provide recommendations for fixing the combination of ordersor increasing efficiency.

The control plan can be generated using order information gathered frommultiple discrete systems. The information may be compiled into onecontrol plan for enabling efficient control and/or operation of varioussystems during the entire manufacturing process. Further, the compiledinformation (or various portions thereof) could be formed into one ormore different formats that are acceptable to various systems during themanufacturing process (e.g., the printer may require a certain fileformat with certain information).

In some embodiments, golden image files can be formed and saved forfuture use, capitalizing on ideal golden image creation times whilestill enabling high volume and efficient manufacturing. Such goldenimages can be provided to a vision system to perform quality checks.Depending on the configuration of the control plan and positioning ofthe orders therein, instructions for the vision system can be providedto match golden images to corresponding lanes of the printing press andproper positions along the control plan.

In an example embodiment, a system for generating a control plan forcontrolling manufacturing of one or more paper-based products isprovided. The system comprises at least one controller configured toreceive a request for generation of a control plan associated with aroll of web product for manufacturing one or more paper-based products.The request includes at least one criteria regarding orders for the oneor more paper-based products. The controller is further configured toprovide a plurality of available orders for paper-based products forselection. Each of the plurality of available orders for selectionsatisfy the at least one criteria from the request and are associatedwith order information. The order information for each order comprisesinformation related to completing manufacturing of a desired productassociated with the order. The order information is gathered from aplurality of discrete systems. The controller is further configured toreceive a selection of an order from the plurality of available ordersand generate the control plan associated with the roll of web product.The control plan includes at least the selected order.

In some embodiments, the at least one criteria for the request forgeneration of the control plan is at least one of an indication of adesired width of the roll of web product or an indication of anavailable printer for use during manufacturing. The printer isconfigured to process a maximum width for the roll of web product. Eachof the plurality of available orders for selection are able to fitwithin either the desired width or the maximum width depending on theindicated criteria with the request.

In some embodiments, the at least one criteria for the request forgeneration of the control plan is at least one of an indication of adesired job type characteristic, order number, or customer.

In some embodiments, the plurality of discrete systems includes at leasta graphics planning system and a management information system. Thegraphics planning system comprises order information related to one ormore desired images for the order. The management information systemcomprises order information related to at least an amount of desiredproduct for the order.

In some embodiments, the at least one controller is configured toprovide a ready status for each of the plurality of available orders forselection. The ready status indicates that the order is ready forproceeding with immediate manufacturing in an instance in which at leastorder information for the order related to printing and sheetformation/processing has been gathered.

In some embodiments, the at least one controller is configured to filtera database of aggregated available orders based on the at least onecriteria from the request to determine the plurality of available ordersto provide for selection.

In some embodiments, the at least one controller is configured todetermine an amount of waste on the roll of web product based on one ormore selected orders and provide an indication of the amount of waste.In some embodiments, the at least one controller is configured todetermine if the amount of waste satisfies an acceptable waste thresholdand provide an indication as to whether the amount of waste satisfiesthe acceptable waste threshold. In some embodiments, the at least onecontroller is configured to determine if the amount of waste satisfiesan acceptable waste threshold and prevent generation of the control planin an instance in which the amount of waste does not satisfy theacceptable waste threshold.

In some embodiments, the selected order is a first order. The at leastone controller is configured to, in response to receiving the selectionof the first order determine a remaining width of the roll of webproduct that is available for one or more orders and provide a secondplurality of available orders for selection. Each of the secondplurality of available orders for selection are able to fit within theremaining width on the roll of web product. In some embodiments, the atleast one controller is configured to provide an indication of one ormore recommended orders from the second plurality of available ordersfor selection. The one or more recommended orders are determined basedon one or more factors associated with the first order. The one or morefactors associated with the first order include at least one ofdeadlines, customers, color profiles, and manufacturing locations. Insome embodiments, the at least one controller is configured to determinethat an available sheet formation/processing system planned for use withthe roll of web product that can accommodate a plurality of lanes priorto providing the second plurality of available orders for selection. Insome embodiments, the at least one controller is configured to receiveinput indicating a desire to split the selected first order into two ormore ribbons for the control plan. In some embodiments, the at least onecontroller is configured to receive a selection of at least one secondorder and provide an optimization up or down function for enabling theoverall number of sheet or box structures for at least one of theselected first order or the selected second order to be reduced orincreased in order to cause an overall length of the roll of web productbeing used for the selected first order to better align with an overalllength of the roll of web product being used for the selected secondorder. In some embodiments, the at least one controller is configured toprovide a recommendation for optimization up or down based on a customerassociated with at least one of the selected first order or the selectedsecond order being willing to receive extra sheet or box structures.

In some embodiments, the at least one controller is configured to, inresponse to receiving a selection of an order, provide a suggested widthfor the roll of web product to minimize a remaining unused width of theroll of web product that is available after including the selectedorder.

In some embodiments, the at least one controller is configured toprovide an indication of one or more recommended orders from theplurality of available orders for selection, wherein the one or morerecommended orders are determined based on one or more factors, whereinthe one or more factors include at least one of upcoming deadlines,customers, and manufacturing locations.

In some embodiments, the selected order includes order informationcorresponding to a total number of desired sheet or box structures and adesired layout for a processing set of sheet or box structures. Eachprocessing set of sheet or box structures includes a plurality of sheetor box structures that are positioned relative to each other to form theprocessing set of sheet or box structures. The at least one controlleris configured to determine, based on the selected order, a number ofsets of sheet or box structures to apply to the control plan to satisfythe total number of desired sheet or box structures for the selectedorder.

In some embodiments, the at least one controller is configured todetermine a size of a web weave to apply to each width end of the rollof web product for the control plan.

In some embodiments, the at least one controller is configured topresent a visual representation of the roll of web product with the atleast one selected order applied.

In some embodiments, the at least one controller is configured toprovide a preview of the roll of web product after printing.

In some embodiments, the at least one controller is configured togenerate a label based on the control plan. The label is configured tobe applied to the roll of web product. In some embodiments, the labelincludes at least one computer readable marking that, upon being read,at least one of identifies the control plan or supplies the controlplan.

In some embodiments, the at least one controller is configured to form aset of printing instructions to enable operation of the printeraccording to the control plan, wherein the set of printing instructionsare formed into a format that is acceptable to the printer. In someembodiments, the set of printing instructions include instructionsregarding a color profile needed by the printer to print desired imagesfor the control plan. In some embodiments, the set of printinginstructions include instructions that cause the printer to perform oneor more test jobs prior to beginning a production run. In someembodiments, the set of printing instructions include instructions thatcause the printer to prepare one or more golden images for use duringone or more quality checks. In some embodiments, the set of printinginstructions include instructions that cause the printer to prepare theone or more golden images during a separate golden image processing run.In some embodiments, the set of printing instructions includeinstructions that cause the printer to prepare the one or more goldenimages during the production run at a specific position within an orderon the control plan.

In some embodiments, the at least one controller is configured to form agolden image file that includes one or more golden images for use duringone or more quality checks for at least the selected order for thecontrol plan. In some embodiments, the at least one controller isconfigured to provide the golden image file to a vision system thatperforms the one or more quality checks. In some embodiments, the atleast one controller is configured to enable access to the golden imagefile by a vision system that performs the one or more quality checks. Insome embodiments, the golden image file includes at least one tolerancelevel associated with the one or more golden images for use by a visionsystem that performs the one or more quality checks to determine if thechecked image is acceptable.

In some embodiments, the at least one controller is configured to form aset of quality check instructions to enable a vision system to performone or more quality checks. The set of quality check instructionsprovides access to one or more golden images for use during the one ormore quality checks for at least the selected order for the controlplan. In some embodiments, the set of quality check instructionsincludes a separate golden image for performing a quality check on eachlane of a multi-lane printing press. In some embodiments, the set ofquality check instructions includes a single golden image that is usedfor performing a quality check on a plurality of lanes of a multi-laneprinting press.

In some embodiments, the at least one controller is configured to form aset of sheet formation/processing instructions to enable operation ofthe sheet formation/processing system according to the control plan,wherein the set of sheet formation/processing instructions are formedinto a format that is acceptable to the sheet formation/processingsystem.

In some embodiments, the at least one controller is configured to trackthe status of the control plan during the manufacturing process.

In another example embodiment, a graphical user interface for generatinga control plan for controlling manufacturing of one or more paper-basedproducts is provided. The graphical user interface being configured toreceive a request for generation of a control plan associated with aroll of web product for manufacturing one or more paper-based products.The request includes at least one criteria regarding orders for the oneor more paper-based products. The graphical user interface is furtherconfigured to provide a plurality of available orders for paper-basedproducts for selection. Each of the plurality of available orders forselection satisfy the at least one criteria from the request and areassociated with order information. The order information for each ordercomprises information related to completing manufacturing of a desiredproduct associated with the order. The order information was gatheredfrom a plurality of discrete systems. The graphical user interface isfurther configured to receive a selection of an order from the pluralityof available orders and generate the control plan associated with theroll of web product, wherein the control plan includes at least theselected order.

In yet another example embodiment, a method for generating a controlplan for controlling manufacturing of one or more paper-based productsis provided. The method comprising receiving a request for generation ofa control plan associated with a roll of web product for manufacturingone or more paper-based products. The request includes at least onecriteria regarding orders for the one or more paper-based products. Themethod further comprises providing a plurality of available orders forpaper-based products for selection. Each of the plurality of availableorders for selection satisfy the at least one criteria from the requestand are associated with order information. The order information foreach order comprises information related to completing manufacturing ofa desired product associated with the order. The order information isgathered from a plurality of discrete systems. The method furthercomprises receiving a selection of an order from the plurality ofavailable orders and generating the control plan associated with theroll of web product, wherein the control plan includes at least theselected order.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1 shows a block diagram of an example paper, sheet, and/or boxmanufacturing process, in accordance with some embodiments discussedherein;

FIG. 2 shows an example platform for various aspects of an examplecorrugated box manufacturing process, in accordance with exampleembodiments described herein;

FIG. 3A shows an example portion of a roll of web product with fourdifferent structure areas, in accordance with some example embodimentsdiscussed herein;

FIG. 3B shows an example portion of a roll of web product, wherein thestructure areas each include a readable marker, in accordance withexample embodiments described herein;

FIG. 4A shows a block diagram of an example paper, sheet, and/or boxmanufacturing system including an example imposition engine module, inaccordance with example embodiments described herein;

FIG. 4B shows a block diagram of a system for enabling generation of acontrol plan for a roll of web product for manufacturing, in accordancewith example embodiments described herein;

FIGS. 5-7 show an example process for a user to enter criteria forsearching for available orders to use in generation of a control plan,in accordance with example embodiments described herein;

FIG. 8 shows available orders for a user to select in generation of acontrol plan, in accordance with example embodiments described herein;

FIG. 9A shows an example pop-up window that indicates that a change hasbeen made to the selected order for the control plan, in accordance withexample embodiments described herein;

FIG. 9B shows an example portion of a roll of web product with a boxstructure outline in a first orientation, in accordance with someexample embodiments discussed herein;

FIG. 9C shows an example portion of a roll of web product with a boxstructure outline in a second orientation, in accordance with someexample embodiments discussed herein;

FIG. 10 shows a visual representation of a control plan and availableadditional orders that may be added to the control plan, in accordancewith example embodiments described herein;

FIG. 11 shows the control plan of FIG. 9A with a second order added anda search feature for locating available additional orders that may beadded to the control plan, in accordance with example embodimentsdescribed herein;

FIG. 12 shows the control plan of FIG. 10, wherein the first order wassplit into two ribbons, in accordance with example embodiments describedherein;

FIG. 13 illustrates selection of a different width of paper for thecontrol plan, in accordance with example embodiments described herein;

FIG. 14 illustrates the control plan generated from selection of adifferent width of paper, wherein a waste amount for the control plan isindicated, in accordance with example embodiments described herein;

FIG. 15 illustrates an optimization up/down feature for generation ofthe control plan, in accordance with example embodiments describedherein;

FIG. 16A shows a preview of the printed roll of web product for thegenerated control plan, in accordance with example embodiments describedherein;

FIG. 16B shows an example portion of a roll of web product passingthrough a press with planned box structure outlines, in accordance withsome example embodiments discussed herein;

FIG. 16C shows four example different use cases for utilizing one ormore golden images during a quality check for a printed roll of webproduct for the generated control plan, wherein the generated controlplan has multiple lanes of printed orders, in accordance with exampleembodiments described herein;

FIG. 17A shows a block diagram of an example corrugated sheet or boxmanufacturing process with print in-line with the corrugator, inaccordance with some embodiments discussed herein;

FIG. 17B shows a block diagram of an example corrugated sheet or boxmanufacturing process with print off-line or near-line, before thecorrugator, in accordance with some embodiments discussed herein;

FIG. 18A illustrates a portion of the corrugated box manufacturingprocess with print in-line with the corrugator, in accordance with someembodiments discussed herein;

FIG. 18B illustrates a portion of the corrugated box manufacturingprocess with print off-line or near-line, before the corrugator, inaccordance with some embodiments discussed herein;

FIG. 19 illustrates a cutting arrangement portion of the corrugated boxmanufacturing process, in accordance with some embodiments discussedherein;

FIG. 20 shows a block diagram of an example folded carton manufacturingprocess, in accordance with some embodiments discussed herein;

FIG. 21 shows a block diagram of an example industrial bag manufacturingprocess, in accordance with some embodiments discussed herein;

FIG. 22 shows a block diagram of an example cup manufacturing process,in accordance with some embodiments discussed herein;

FIG. 23 shows a block diagram of an example paper plate manufacturingprocess, in accordance with some embodiments discussed herein; and

FIG. 24 illustrates a flowchart of an example method for generating acontrol plan for a roll of web product for a manufacturing process, inaccordance with some embodiments discussed herein.

DETAILED DESCRIPTION

Some example embodiments now will be described more fully hereinafterwith reference to the accompanying drawings, in which some, but not allexample embodiments are shown. Indeed, the examples described andpictured herein should not be construed as being limiting as to thescope, applicability or configuration of the present disclosure. Rather,these example embodiments are provided so that this disclosure willsatisfy applicable legal requirements. Like reference numerals refer tolike elements throughout.

Example Paper, Sheet, or Box and Other Manufacturing Process

FIG. 1 illustrates an example paper, sheet, or box manufacturing process10 to form one or more paper-based products, according to variousembodiments of the present invention. The manufacturing process 10includes a number of phases that result in a finished product that isshaped and printed per the customer's order. The process 10 may includean ordering phase 12, a planning phase 14, a print phase 30, a reeleditor phase 40, a sheet formation/processing phase 60, a finishingphase 70, and a tracking/logistics phase 80.

Depending on the desired configuration, one or more controller(s) 90 maybe used to control one or more various phases (e.g., varioussystems/devices therein) of the manufacturing process 10. In someembodiments, less or more phases or different orders of phases arecontemplated. Some embodiments of the present invention are contemplatedfor any type of paper, sheet, or box product manufacturing, includingprinted paper-based product manufacturing, such as corrugate, foldedcarton, beverage labels, flexible paper, industrial bags, plates, cups,décor, and many others.

In some embodiments, the controller 90 may be configured to controloperation of one or more printing presses during the printing phase 30,operation of one or more reel editor(s) for one or more lanes during thereel editor phase 40, operation of various components used during thesheet formation/processing phase 60, and/or operation of variouscomponents used during the finishing phase 70. Likewise, the controller90 may be used with the ordering phase 12 and/or during thetracking/logistics phase 80, such as described herein. In someembodiments, the controller 90 may be spread over any number ofcontrollers at any of the various phases of the manufacturing process10.

As described in more detail herein, the controller 90 provides logic andcontrol functionality used during operation of various components/phasesof the manufacturing process 10. In some embodiments, the functionalityof the controller 90 may be distributed to several controllers that eachprovides more limited functionality to discrete portions of theoperation of manufacturing process 10.

The controller 90 may comprise one or more suitable electronicdevice(s)/server(s) capable of executing described functionality viahardware and/or software control. In some embodiments, the controller 90may include one or more user interfaces (not shown), such as fordisplaying information and/or accepting instructions. The controller 90can be, but is not limited to, a microprocessor, microcomputer, aminicomputer, an optical computer, a board computer, a complexinstruction set computer, an ASIC (application specific integratedcircuit), a reduced instruction set computer, an analog computer, adigital computer, a molecular computer, a quantum computer, a cellularcomputer, a solid-state computer, a single-board computer, a bufferedcomputer, a computer network, a desktop computer, a laptop computer, apersonal digital assistant (PDA) or a hybrid of any of the foregoing.

The controller 90 may include one or more processors coupled to a memorydevice. Controller 90 may optionally be connected to one or moreinput/output (I/O) controllers or data interface devices (not shown).The memory may be any suitable form of memory such as an EPROM (ErasableProgrammable Read Only Memory) chip, a flash memory chip, a disk drive,or the like. As such, the memory may store various data, protocols,instructions, computer program code, operational parameters, etc. Inthis regard, controller may include operation control methods embodiedin application code. These methods are embodied in computer instructionswritten to be executed by one or more processors, typically in the formof software. The software can be encoded in any suitable language,including, but not limited to, machine language, assembly language, VHDL(Verilog Hardware Description Language), VHSIC HDL (Very High Speed ICHardware Description Language), Fortran (formula translation), C, C++,Visual C++, Java, ALGOL (algorithmic language), BASIC (beginnersall-purpose symbolic instruction code), visual BASIC, ActiveX, HTML(HyperText Markup Language), and any combination or derivative of atleast one of the foregoing. Additionally, an operator can use anexisting software application such as a spreadsheet or database andcorrelate various cells with the variables enumerated in the algorithms.Furthermore, the software can be independent of other software ordependent upon other software, such as in the form of integratedsoftware. In this regard, in some embodiments, the controller 90 may beconfigured to execute computer program code instructions to performaspects of various embodiments of the present invention describedherein.

In the ordering phase 12, a customer may supply an order that includesdesired characteristics for the end product. For example, the customermay provide a number of desired sheet, paper, or box structures(including for example labels, cartons, bags, plates, cups, décor,etc.), shape requirements, one or more images/designs for printing onthe structures, color specifications, among many others. In someembodiments, the customer may input such an order through a webinterface. The web interface may enable the customer to easily input thedesired characteristics of the order electronically, such as forming adesign for the desired end product(s). The web interface may also enablethe customer to perform many related tasks, including, for example,updating orders, tracking orders, handling payment, requestingassistance, setting up automated ordering (e.g., recurring ordering),viewing and approving example images (“soft proofing”), viewing exampleend products, etc.

In addition to providing increased efficiency of process for thecustomer, the web interface may also directly interact with and provideinformation for automated processes useful in the remainder of themanufacturing process 10. For example, the information from the webinterface may be fed directly into a controller 90 and utilizedaccordingly. For example, as described herein, the information from theweb interface may be used to form a control plan (e.g., reel map, printplan, process plan, etc.) for a planned roll of web product (such as maybe used to form the desired end product(s)). Additionally, however, theinformation from the web interface may be used to provide on-the-flyupdates or adjustments to the manufacturing process. Further, feedback(e.g., from the controller 90) may be provided back to the web interfacefor the customer, such as tracking information, images of the completedsheet or box structures, among other things.

In some embodiments, the controller 90 may be configured to aggregatereceived orders, such as in one or more databases.

In some embodiments, the controller 90 (such as during the planningphase 14) may be configured to generate (e.g., form) a control planassociated with a roll of web product. In some embodiments, a controlplan may be electronic-based (e.g., an electronicmap/plan/table/listing/etc.) that is reference-able for determining howthe various components of the manufacturing process 10 shouldoperate—such as to form the desired product through the manufacturingprocess 10.

In some embodiments, the controller 90 may be configured to generate acontrol plan associated with a roll of web product for at least oneorder for the one or more paper-based products from among a plurality oforders. In this regard, each order of the plurality of orders maycomprise at least one design for at least one paper-based product, andthe design may include one or more printed images (such as for beingprinted on the desired product).

In some embodiments, the control plan includes one or more sets of orderinstructions. In some embodiments, each set of order instructions maycorrespond to a different order that is planned to be manufactured usingthe generated control plan. For example, a control plan may include aset of first order instructions for forming a first paper-based productfrom the roll of web product for fulfilling a first order. Additionally,in some embodiments, a control plan may have a second or more sets oforder instructions, such as to control manufacturing of additionalproducts. In some cases, depending on the size restrictions of the orderand/or the systems used during the manufacturing process, the controlplan may be generated such that different orders are positioned orplanned to be adjacent to each other in a width direction (e.g., next toeach other) on a roll of web product. Additionally or alternatively, thecontrol plan may be generated such that different orders are positionedor planned to run one after the other in a length direction on a roll ofweb product.

The order instructions for the control plan for each order may includeone or more instructions, specification, databases, etc. for enablingcontrol and/or operation of various systems/devices of the manufacturingprocess 10. For example, the set of first order instructions maycomprise first plan instructions for forming one or more first sheet orbox structure areas on the roll of web product. Further, the first planinstructions may include one or more printed images for each of thefirst sheet or box structure areas. Ultimately, in some embodiments, theplan instructions (and other instructions) that form the set of orderinstructions may be used during the manufacturing process 10 to form thedesired product.

In some embodiments, a control plan (such as through the planinstructions) may provide a layout of the order and/or arrangement ofsheet or box structure areas on a roll of web product that are to beprinted on, formed, and/or cut during the manufacturing process 10. Forexample, a control plan (e.g., reel map) for the section of web product220 shown in FIG. 3A may include indications that there should be 4structures (A, B, C, and D) that are arranged as shown. In someembodiments, the control plan (or a portion thereof) may berepresentable in visual form, such as to a person (or persons), whichmay be useful for manually checking the control plan for accuracy,efficiency, and/or operating the corrugator. In some embodiments,electronic verification of such checking could occur either with orwithout the visual representation of the control plan.

The manufacturing process 10 may also including the printing phase 30.Depending on the desired manufacturing process 10, digital printprocesses can be used, providing for enhanced image quality. During theprinting phase 30, the controller 90 may direct the press digital frontend (DFE) and raster image processor (RIP), etc., to print one or moreimages at specific locations on the web product. In some embodiments,the controller 90 may utilize the control plan to determine where on theweb to print the images and/or markers. In some embodiments, thecontroller 90 may provide the control plan to the printer for operationthereof to cause the printer to print the desired image at anappropriate position on the roll of web product (e.g., within each sheetor box structure area)—thereby forming a roll of printed web product.For example, an image selected by the customer (such as a bottle), maybe printed in the center (or other section) of a structure—such as mayultimately be visible for marketing or other purposes once the structureis formed. Any image (including, words, marks, instructions, etc.) iscontemplated by various embodiments of the present invention.

In some embodiments, one or more markers can be printed on the webproduct, including any marker that may be used by various components ofthe manufacturing process 10, such as for tracking, cutting, printing,etc. Further description regarding possible markers and theirutilization is provided in greater detail herein. In this regard, thecontroller 90 may be connected to one or more vision systems that areused to read or detect color, defects, structure, and various markersfor controlling and/or operating various components/phases of themanufacturing process 10.

During the reel editor phase 40, the controller 90 may direct operationof a reel editor to edit (e.g., remove) waste from the roll of printedweb product. For example, the controller 90 (such as during the printphase 30 and/or a separate/different phase) may be configured todetermine waste that is on the roll of printed web product. Such wastecould be unprinted sections of the roll and/or poor qualityimages/defects in the roll.

In some embodiments, the controller 90 is configured to provide thecontrol plan to at least one reel editor for controlling operation ofthe reel editor. In such an example embodiment, the control plan mayinclude editing instructions (e.g., within the set of orderinstructions) to control operation of the reel editor to cause one ormore portions of the roll of printed web product to be removed. In someembodiments, the editing instructions may cause the reel editor to slitthe roll of web product into more than one child roll (e.g., narrower inpaper width) and/or to break the roll of web product into more than onechild roll (e.g., narrower in paper roll diameter). Such child rolls maybe designed for processing through various manufacturing systemsdownstream and may, in some instances, assist in tracking and/or ordermanagement.

Once edited, the controller 90 may determine and update the control planto account for any removed waste and/or one or more newly formed childroll(s).

During the sheet formation/processing phase 60, the controller 90 may beconfigured to perform one or more processes to form and/or process theroll of web product in formation of the desired end product. In someembodiments, the controller 90 may be configured to provide the controlplan to at least one sheet formation/processing system for controllingoperation of the sheet formation/processing system. The sheetformation/processing system may include one or more systems for theformation/processing of the roll of web product, such as forming theroll of web product into one or more sheets (or structures) that may beutilized in the remainder of the manufacturing process 10.

As used herein, “sheet formation/processing” may refer to any formationor processing of a sheet or structure from a roll of web product, suchas for example cutting/forming a rectangular shaped structure that canbe, in some embodiments, further processed (e.g., in the finishingphase) to form (or help form) one or more paper-based products. In someembodiments, during the sheet formation/processing phase 60, the roll ofweb product (or portions thereof) may be formed into additional layeredproduct that can be cut into sheets, such as when processed through acorrugator. In some embodiments, further processing may occur during thesheet formation/processing phase 60 and/or finishing phase 70. Forexample, the formed sheet may be die-cut, such as during either phase.

In some embodiments, the sheet formation/processing system may include aweb forming device that is configured to use the roll of printed webproduct to form an updated web. The control plan (such as in the set oforder instructions) may include web forming instructions to controloperation of the web forming device to cause the updated web to beformed. In some example embodiments, the updated web may includeadditional layers of material (e.g., additional webs for added support,glue, fluting, lamination, etc.). In this regard, the updated web may beused for forming the desired end product.

In some embodiments, the sheet formation/processing system may includeat least one cutting arrangement (e.g., one or more cutting devices)that is configured to cut a portion of the roll of printed web product.The control plan (such as in the set of order instructions) may includecutting instructions to control operation of the cutting arrangement tocause one or more sheet or box structures with the printed image thereinto be cut from the roll of printed web product. In such an example, theone or more sheet or box structures with the first printed image thereinmay then be utilized to form the desired paper-based product forfulfilling the order.

For example, as described in greater detail herein, an examplemanufacturing process is corrugated box manufacturing and thatmanufacturing process may include a board making phase and/or cuttingphase (see e.g., FIGS. 4A and 4B). In such an example, the board makingphase may be performed under operation of one or more web formingdevices (e.g., using a corrugator). Additionally, the cutting phase maybe performed under operation of one or more cutting devices (e.g., usinga corrugator). In some embodiments, other manufacturing processes arealso contemplated—providing different sheet formation/processing phases60, such as for use with carton formation, plate formation, cupformation, bag formation, etc.

Referring back to FIG. 1, with the sheets formed/processed, themanufacturing process 10 may continue to the finishing phase 70. Thefinishing phase 70 may include additional printing, additional cutting(e.g., die-cutting), additional scoring, additional gluing, and/or othernecessary functions to achieve a finished product for sending to thecustomer.

In some embodiments, the controller 90 is configured to provide thecontrol plan to at least one finishing system for controlling operationof the finishing system. The control plan (such as in the set of orderinstructions) may include finishing instructions to control operation ofthe finishing system to cause one or more products to be formed, such asusing the sheets from the sheet formation/processing phase.

In some embodiments, the finishing system may comprise a die-cutter forforming a shaped sheet and/or product. In such an example, the finishinginstructions from the control plan may cause the die-cutter to cut thesheet and/or roll from the sheet formation/processing phase 60 into adesired shape.

In some embodiments, the finishing system may comprise a folding/gluingdevice that is configured to fold and/or glue the one or more sheet orbox structures for use in formation of the one or more desired products(e.g., folded cartons). In such an example, the finishing instructionsfrom the control plan may cause the folding device to fold and glue theone or more sheet or box structures into the one or more folded cartons.

In some embodiments, the finishing system may comprise a tuber devicethat is configured to form the one or more sheet or box structures intoone or more tubes and/or a bottoming device that is configured to form abottom for each of the one or more tubes for use in formation of thedesired products (e.g., an industrial bag). In such an example, thefinishing instructions from the control plan may cause the tuber deviceto form the one or more sheet or box structures into one or more tubesand the bottoming device to form a bottom of each tube for use information of the desired product.

In some embodiments, the finishing system may comprise a cup formingdevice that is configured to form the one or more sheet or boxstructures into one or more desired products (e.g., cups). In such anexample, the finishing instructions from the control plan may cause thecup forming device to form the one or more sheet or box structures intoone or more cups.

In some embodiments, the finishing system may comprise a plate formingdevice that is configured to form the one or more sheet or boxstructures into one or more desired products (e.g., paper plates). Insuch an example, the finishing instructions from the control plan maycause the plate forming device to form the one or more sheet or boxstructures into one or more plates.

In some embodiments, the controller 90 is configured to determine if theone or more products formed by the finishing system satisfy a particularorder. For example, in some embodiments, a vision system or other visualinspection system may be used to confirm accuracy and/or separating ofthe order(s) during the manufacturing process.

The manufacturing process 10 may also include a tracking/logistics phase80 that includes tracking the finished sheet or box structures and/orpreparing/delivering them to the customer. In some embodiments, one ormore tracking or counting systems can be implemented upstream in themanufacturing process 10, such as to enable tracking/logistic planningthroughout the manufacturing process 10. In such a regard, in someembodiments, the controller 90 is configured to track one or morewebs/sheets/products during the manufacturing process 10. In someembodiments, unique codes based on the product type (e.g., corrugate,folded carton, industrial bag, plate, cup, décor, etc.) may be used todifferentiate control plans and manufacturing processes.

Example Platform for Managing Manufacturing

FIG. 2 illustrates an example platform 100 for managing paper, sheet, orbox manufacturing according to various embodiments of the presentinvention. Though some of the following description is provided forexample corrugated box manufacturing, some embodiments of the presentinvention contemplate use of the platform (or various aspects of theplatform) for any product manufacturing, such as corrugated boxes,folded carton, beverage containers, labels, flexible paper, industrialbags, plates, cups, décor, and many others.

The platform 100 includes a number of platform modules that interactwith each other to form an integrated platform that provides efficientmanufacturing processes. In the depicted embodiment, the platform 100includes a web interface module 105, a structure module 110, a graphicsfile workflow module 115, a graphics file management module 120, amanagement information systems (MIS) module 125, an imposition enginemodule 130, a variable data engine module 135, a press module 140, acolor management module 148, a press vision system module 145, a reelmanifest module 150, a customer insights module 152, a reel editormodule 155, a corrugator controls module 160, and an enterprise resourceplanning (ERP)/corrugator planning module 165. As described herein, thevarious modules each contain features that are designed to work togetherto provide an integrated, efficient platform 100 for manufacturingcorrugated sheet or box structures for customers. In some embodiments,the controller 90 may be configured to communicate with and/or controloperation of many of the various modules. While the depicted embodimentshows various particular modules, some embodiments of the presentinvention contemplate many variations, including additional modules andcombinations in whole or part of shown modules to form a platform.

The web interface module 105 may be configured to provide forinteraction between customers, users, and the platform 100. For example,the web interface module 105 may be configured to provide an interfacefor a customer to provide information to the platform 100, such asorders, changes to orders, payments, etc. The web interface module mayalso enable additional features, such as enabling a customer to printsamples, upload their own art/images, track orders, among other things.Additionally, however, the web interface module 105 may be helpful forinternal use, such as for tracking sales. The internal web interface maydisplay pertinent information to the company, such as trends, etc. Theweb interface module 105 may communicate, for example, with thestructure module 110, the workflow module 115, the managementinformation systems module 125, and/or the ERP/corrugator planningmodule 165.

The structure module 110 may be configured to enable selection anddesign of the structures planned for manufacture. For example, thestructure module 110 may enable selection of the types of boxes (e.g.,the material, number of layers, flute medium, etc.). Additionally, thesize and shape of the sheet or box structure may be configured using thestructure module 110. In some embodiments, preferred structurespecifications may be stored by the structure module 110. Further, rulesor other constraints may be communicated to the customer and/or utilizedin determination of the sheet or box structure specifications. Thestructure module 110 may communicate, for example, with the webinterface module 105, the workflow module 115, and/or the graphics filemanagement module 120.

The workflow module 115 may be configured to help process the flow ofgraphics orders and facilitate input of the orders into the structuremodule 110 and the graphics file management module 120. In this regard,the workflow module 115 may communicate with the web interface module105, the structure module 110, and/or the graphics file managementmodule 120.

The graphics file management module 120 may be configured to helpprocess the graphics files for use in designing and printing on thesheet or box structures. For example, the graphics file managementmodule 120 may include a repository of available images. Likewise, thegraphics file management module 120 may store new images uploaded by thecustomer. Further, the graphics file management module 120 may includerules or other feature constraints that can be communicated to thecustomer and/or implemented when forming the orders. The graphics filemanagement module 120 may communicate, for example, with the structuremodule 110, the workflow module 115, the management information systemmodule 125, the color management module 148, and/or the impositionengine 130.

The management information system module 125 may be configured to store,process, and organize the information for the platform 100. For example,the management information systems module 125 is configured to receiveand organize the orders, other customer requests, and internalinformation from the web interface module 105. Further, the data fromthe graphics file management module 120, imposition engine module 130,and ERP/corrugator planning module 165 may be stored and organized usingthe management information systems module 125. The managementinformation systems module 125 may communicate, for example, with theweb interface module 105, the graphics file management module 120, theimposition engine 130, and/or the ERP/corrugator planning module 165.

The enterprise resource planning (ERP)/corrugator planning module 165may be configured to facilitate planning and implementation of themanufacturing process. In this regard, the ERP/corrugator planningmodule 165 may receive data from various features of the platform 100and process the information to plan out efficient manufacturingprocesses across the entire platform. For example, the ERP/corrugatorplanning module 165 may receive data from the web interface module 105,the management information systems module 125, the press module 140, thevision system module 145, the corrugator controls module 160, and reeleditor module 155 to inform planning for future jobs. As an example, themanagement information systems module 125 may provide order informationto the ERP/corrugator planning module 165, which can be utilized to formjob tickets for the imposition engine module 130. The ERP/corrugatorplanning module 165 may also be configured to enable printing ofschedules for jobs etc.—which may be used for tracking or otherpurposes. Such information, for example, may be used to provideinformation back to the customer, such as through the web interfacemodule 105. The ERP/corrugator planning module 165 may communicate, forexample, with the web interface module 105, the management informationsystems module 125, the imposition engine module 130, the press module140, the vision system module 145, the reel editor module 155, and/orthe corrugator controls module 160.

The imposition engine module 130 may be configured to plan outimposition of print objects (e.g., images or markers) and other variabledata on the roll of web product (e.g., corrugated board web). Forexample, the imposition engine module 130 may gather ready job tickets(e.g., customer orders), such as from the management information systemsmodule 125 and/or ERP/corrugator planning module 165, for impositionacross rolls of web of product. Using the job tickets, the impositionengine module 130 may determine layouts for the rolls of web productthat minimize waste and improve processes. In order to plan out andfinalize impositions, the imposition engine module 130 may receiveinformation from various other modules, such as the graphics filemanagement module 120, the variable data engine module 135, and the reelmanifest module 150.

In some embodiments, the imposition engine module 130 may provide theability to test roll layouts and finalize acceptable roll layouts. Inthis regard, formation of the layouts may be optimized based on manydifferent factors, including, for example, roll/sheet/finished boxrequirements, press limitations, downstream corrugation, die-cutoptimization, among other things. After finalization, the impositionengine module 130 may be configured to pass the imposed layout to thepress module 140 for printing.

The imposition engine module 130 may communicate, for example, with thegraphics file management module 120, the management information systemsmodule 125, the ERP/corrugator planning module 165, the variable dataengine module 135, the reel manifest module 155, and the press module140.

In some embodiments, the imposition engine module 130 may be configuredto enable a user to form a control plan that may include instructionsfor operation of various systems of the manufacturing processes (e.g.,the corrugator, printer, reel editor, etc.). In some such embodiments,the imposition engine module 130 may provide suggestions and/or automateformation (or portions thereof) of the control plan. For example,various orders from customers may be submitted. The imposition enginemodule 130 may be configured to receive the orders and store and/orgather specific order information regarding the orders (e.g., number ofboxes, box types, quality requirements, printing information, ordertimeline, type of paper, width and length requirements, customerinformation, etc.). The imposition engine module 130 may be configuredto utilize such order data to enable optimization of an upcoming controlplan for a roll of web product, such as to minimize waste, meet orderdeadlines, utilize similar printing techniques, colors, or othercapabilities. For example, similar orders may be “imposed” on a roll ofweb product according to a control plan.

In some embodiments, the imposition engine module 130 may be configuredto provide an interface (or information to an interface) to enable auser to form one or more control plans. In such example embodiments, auser may select available orders for filling out the control plan(s).The imposition engine module 130 may provide recommendations based onany number of factors, including, for example, number of boxes, boxtypes, quality requirements, printing information, order timeline, typeof paper, width and length requirements, customer preferences, locationof manufacturing facilities, etc. In some embodiments, therecommendations may be provided with an aim to reduce waste. Otherpossible considerations include meeting customer needs or manufacturingcapabilities/preferences.

In some embodiments, the imposition engine module 130 may be configuredto test (e.g., theoretically) one or more possible control plans toconfirm that one or more predetermined rules are followed. Such examplerules may be related to various limitations, such as paper size, paperquality, printer quality, location of the manufacturing, order size,among many other things. For example, a single customer order may not besplit between locations of manufacturing. If an error is found, an errormessage and possibly a suggestion for revision may be provided to theuser. In some embodiments, the imposition engine module 130 may beconfigured to prevent such creation of a control plan if a rule check isfailed.

In some embodiments, the imposition engine module 130 may be configuredto optimize an order up or down in quantity, such as to reduce waste.For example, some customer orders may have the ability to receive extrabox structures (e.g., exceed the order by 10%). Further, in a multi-lanemanufacturing process, it may be desirable to ensure that both lanes ofthe roll “complete” at the same position, thereby avoiding one of thelanes having wasted webbing. In order to account for this, certainorders may be optimized up or down depending on any customerpreferences. As an example, a customer order may allow for exceeding thenumber of provided box structures by 10%. In that case, if that order isnear the end of the roll plan and there is extra space in that lane, theimposition engine module 130 may be configured to “add” more boxstructures beyond the original order amount (e.g., up to 10%) in orderto make sure both lanes complete at or near the same place. In anotherexample, perhaps the order does not allow for excess box structures. Inthat case, the imposition engine module 130 may be configured cut offthe order in a lane in order to have both lanes complete at or near thesame place. Then, the imposition engine module 130 may store anindication of an “incomplete” order—which can be provided to a user forplanning another roll plan.

In some embodiments, the imposition engine module 130 may take data frommany different sources and form a control plan that can be utilizedthroughout the manufacturing process. In this regard, the impositionengine module 130, in some embodiments, may form one or more fileformats that are readable/acceptable by the different stages/machines ofthe manufacturing process (e.g., the printing press, the corrugator,reel editor, etc.).

In some embodiments, the imposition engine module 130 may be configuredto receive feedback from the one or more of the manufacturing processes.For example, the printing press may provide information regarding thecontrol plan that was just printed back to the imposition engine module130 (e.g., how much waste was created, job information, customerinformation, ink used, error handling, etc.). Such information can bestored by the imposition engine module 130 and used in various stages ofthe manufacturing process. For example, the information can be used tooptimize future control plans. In some embodiments, a tag/label can beprinted with that information and put on the roll for easyaccess/information gathering.

In some embodiments, the imposition engine module 130 may be configuredto provide a job management queue and error/exception handling systemfor the printing press module 140. For example, in some embodiments theimposition engine module 130 may be configured to determine whichcontrol plan to send to which manufacturing system and handle thecontrol plans accordingly. Further, in some embodiments, depending onthe feedback received, the imposition engine module 130 may beconfigured to determine the occurrence of one or more errors orunsatisfactory completion attempts. Accordingly, the imposition enginemodule 130 may be configured to determine where to send the control planto fix or redo such work. In some embodiments, the imposition enginemodule 130 may update the control plan based on the one or more errorsor unsatisfactory completion attempts.

In some embodiments, the imposition engine module 130 may be configuredto instruct the printing press module 140 to generate golden referenceimage(s) to be used by the vision system module 145 for comparison. Insome embodiments, the imposition engine module 130 may be configured toprovide reference to the golden reference image to be used by the visionsystem module 145 for comparison, such for use during quality checks.

The variable data engine module 135 may be configured to manage markersand other variable data through the manufacturing process. As describedherein, some embodiments of the present invention contemplate use ofmarkers for automated control during the manufacturing process, such forautomated control/operation of the reel editor. Depending on theconfiguration of the manufacturing process, different markers or othervariable data may be utilized to achieve automated control. The variabledata engine module 135 may be configured to track, organize, determine,and report on such markers or other variable data.

In some embodiments, the variable data engine module 135 may be aweb-based back-office function that assigns/allocates, references,and/or reports on variable data/marker information utilization. Such amodule may enable generation and allocation of group (multi-use)individual barcodes, quick response (QR) codes, watermarks, colormarkers, and general variable data. In some embodiments, the variabledata engine module 135 may assign/allocate variable data/markers byvarious entities, such as brand, product type, printer type, convertertype, corrugator, logistics supply chain, or other factors.

In some embodiments, the variable data engine module 135 may transfersuch information to the imposition engine module 130 for imposing on theboard or web layout. In some embodiments, downstream information can beprovided back to and utilized by the variable data engine module 135,such as information from the vision system module 145, reel editormodule 155, corrugator, finishing equipment, logistics control,retailer, brand, and/or customer. Likewise, status updates can beprovided to and from the variable data engine module 135.

In some embodiments, the data generated by the variable data enginemodule 135 may be tracked and utilized for reporting and determinationof optimized processes. Further analytics and usage reporting may begenerated. Along these lines, such information and leanings may beapplicable to manufacturing of other products, such as also contemplatedherein.

The variable data engine module 135 may communicate, for example, withthe graphics file management module 120, the imposition engine module130, the customer insights module 152, and the press module 140.

The press module 140 may be configured to print objects (e.g., imagesand markers) on the roll of web product, such as during the printingphase 30 described herein. Depending on capabilities of the press,different image qualities and efficiencies may be achieved. The pressmodule 140 may be configured to communicate with, for example, theimposition engine module 130, the variable data engine module 135, thereel manifest module 150, the vision system module 145, and the colorprofiles module 148.

The color management module 148 may be configured to store and providecolor profile information for the press module 140. In this regard, thecolor profiles module 148 may manage specific color profiles forcustomers, presses, substrates, or other requirements, that are thenused by the press during printing. The color management module 148 maybe configured to communicate with, for example, the graphics filemanagement module 120 and the press module 140.

The vision system module 145 may be configured to update the graphicsfile management module 120 to store and access golden reference imagesfor print quality comparison.

The vision system module 145 may be configured to perform many differenttypes of vision (e.g., detection) related functions during themanufacturing process 10. In this regard, the vision system module 145may be configured for use during the printing process and/or during useof the reel editor or other components of the manufacturing process 10.In describing such an example vision system module 145, some embodimentsof the present invention contemplate separating described functions ofthe vision system module. For example, a portion of the vision systemmodule 145 may be used during the printing process, while anotherportion of the vision system module 145 may be used in conjunction withoperation of the reel editor or other component. Likewise, there may beseparate functions performed by separate vision system relatedcomponents (e.g., a visual inspection system may inspect the sheet orbox structures for accuracy and a detector may detect one or moremarkers). As such, though described as one module, the followingdescription is not meant to limit the structure of the modules of theplatform 10, as there may be separate vision related modules asappropriate.

The vision system module 145 may be configured to detect informationduring the manufacturing process, such as during use of the printingprocess. In some embodiments, the vision system module 145 may beconfigured to detect possible defects and/or confirm accuracy of printjobs. In such a regard, high quality can be maintained (e.g., confirmingcolor consistency on orders). For example, the vision system module 145may detect defects, such as serious banding, print registrationcolor-to-color, spit-on-page issues, bar/QR code scanability, over-printvarnish issues.

In some embodiments, the vision system module 145 may be configured todetect information during the manufacturing process 10, including duringthe printing phase 30, reel editor phase 40, and/or productformation/processing phase 60. For example, the vision system module 145may detect any defects or issues with the various components of themanufacturing process 10 (e.g., the printer, reel editor, or othercomponent). Additionally, the vision system module 145 may communicatepotential issues in real time to the controller 90 to adjust operationto address any issues. By detecting and communicating such issues, thecontroller 90 may adapt operation to avoid unnecessary waste. Alongthese lines, in some embodiments, the controller 90 may work with thevarious modules of the platform 100 to switch production, such as to adifferent portion of a reel map to avoid down time. In this regard, thevision system module 145 provides for the ability for on-the-flyadjustments during the manufacturing process.

In some embodiments, the vision system module 145 may be configured todetect various markers as the roll of web product progress throughvarious components (e.g., through the printer, reel editor, acorrugator, etc.). Based on the detected markers, the vision systemmodule 145 may provide information to the controller 90 foroperation/control accordingly. Further, such information can be used fortracking orders and status.

In some embodiments, photographs (e.g., digital images) can be taken andstored for evidence or additional learning. In some embodiments, thephotographs could be automatically provided to the customer forverification and auditing purposes.

The vision system module 145 may be configured to communicate, forexample, with the press module 140, the customer insights module 152,the reel manifest module 150, and/or the ERP/corrugator planning module165.

The customer insights module 152 may be configured to determine insightsthat may be useful for obtaining efficiencies, such as for a customer.The insights may be related to, for example, trends for customers,trends that the customer may find desirable, suggestions for thecustomer for future orders, etc. Additionally or alternatively, theinsights may be related to achieving efficiencies for preparing productfor specific customers. For example, the customer may indicate thatcertain “defects” are not important or not really defects as recognizedby the vision system module 145.

In some embodiments, the customer insights module 152 may track andutilize non-customer specific information, such as for determininggeneral efficiencies of process. For example, the module may trackvariable data/marker usage, reel map trends and usages, printer data,print head usage, paper waste, etc., such as to help form insights toincrease efficient manufacturing processes.

The customer insights module 152 may be configured to communicate with,for example, the variable data engine 135, the vision system module 145,and/or the reel manifest module 150.

The reel manifest module 150 may be configured to store and/or track theprocess flow (e.g., reel map) for the manufacturing process. The reelmanifest module 150 works with the imposition engine module 130 to storethe job layouts for operation during the manufacturing process 10. Thereel manifest 150 may be checked, such as by the controller 90, to helpdetermine the current position on a reel map—such as in response toreceiving a detection (e.g., a marker or a defect) from the visionsystem module 145. Further, the corresponding information needed tooperate the corrugator according to the reel map may be stored at thereel manifest module 150 and provided to the controller 90 so that thecontroller 90 may operate the corrugator accordingly. The reel manifestmodule 150 may work with the reel editor module 155 to edit the reel mapin real time, such as described herein. The reel manifest module 150 maybe configured to communicate with, for example, the customer insightsmodule 152, the imposition engine module 130, the press module 140, thevision system module 145, the corrugator controls module 160, and/or thereel editor module 155.

The reel editor module 155 may be configured to enable editing of theprocess flow, such as the reel map. In this regard, in some embodiments,the reel editor module 155 interacts with the reel manifest module 150to update the stored reel map. In some embodiments, the reel editormodule 155 may work with the vision system module 145 to identifyunnecessary waste, which can be edited from the reel map, such as basedon instructions for the controller 90. Such example information can alsobe provided to the ERP/corrugator planning module 165 to update the reelmap and/or for consideration in future jobs. The reel editor module 155may be configured to communicate, for example, with the reel manifestmodule 150, the vision system module 145, and the ERP/corrugatorplanning module 165.

The corrugator controls module 160 may be configured to controloperation of the corrugator, such as described herein. In someembodiments, the corrugator controls module 160 may work with one ormore cameras/detectors to detect information (e.g., markers or defects)that can be used to control/adjust operation of the corrugator. Forexample, the cameras/detectors may detect a marker and the corrugatorcontrols module 160 may determine how to operate the corrugator based onthe detected marker (and/or the corresponding position of the reel map).Then, based on the determined desired operations, the corrugatorcontrols module 160 may cause operation of the corrugator. For example,the corrugator controls module 160 may cause one or more knives tochange position and/or perform a cut. Additional information regardingcontemplated control through detection of markers is provided in greaterdetail herein. The corrugator controls module 160 may be configured tocommunicate with, for example, the reel manifest module 150, the visionsystem module 145, and the ERP/corrugator planning module 165.

In some embodiments, other components/machines and their correspondingcontrols may replace the corrugator, such as components/machines gearedtoward manufacturing of other products.

Example Structures and Orders for a Roll of Web Product

FIG. 3A shows an example arrangement of structures A, B, C, and D on aroll of web product 220, such as after the printing phase 30, and may,in some embodiments, form a representation of a control plan. Prior toprinting, however, the roll of web product is blank such that there isno information thereon. In this regard, the controller 90 operates thevarious components of the printing phase 30 to form printed imagesand/or markers on the blank roll of web product to begin forming thedesired structures. In the depicted example of FIG. 3A, the portion ofthe roll of web product 220 includes a number of first structures (A,291), a number of second structures (B, 292), a number of thirdstructures (C, 293), and a number of fourth structures (D, 294). Theroll of web product 220 also includes some unused (scrap) sections 299and potentially some waste between order changes down web, such asbetween structures A/B and structures C/D (though not shown in theexample of FIG. 3A).

In some embodiments, the present invention contemplates use of areadable marker to enable efficient control and/or operation of variouscomponents of the manufacturing process 10. The present invention, insome embodiments, contemplates utilizing one or more markers on the rollof web product that is printed on the press and “read” to enable controlof the various components of the manufacturing process 10. By “reading”the marker, the controller 90 can determine how to operate—such as byreferring to a control plan associated with the roll of printed webproduct and determining the position along the control plan by virtue ofthe read marker. The marker can also be used in tracking the boxes forpositioning in proper stacks and/or determining completion status of anorder. The present invention contemplates many different types ofmarkers (e.g., QR codes, bar codes, color marks, instructionsthemselves, etc.).

FIG. 3B illustrates an example portion of a roll of web product 220′that includes readable markers 270 a-d. Notably, each structure includesa different readable marker. For example, structure A, 291 has acorresponding readable marker 270 a; structure B, 292 has acorresponding readable marker 270 b; structure C, 293 has acorresponding readable marker 270 c; and structure D, 294 has acorresponding readable marker 270 d. Though the depicted embodimentshows the readable marker positioned within a sheet or box structure, insome embodiments, the readable marker may be positioned in the marginsor other waste area, but still associated with the correspondingstructure (or order section with the one or more structures).

One or more detectors 210 may be positioned along the pathway throughthe various components operating for the roll of web product (e.g., aprinter, a reel editor, a corrugator, finishing, etc.). In this regard,the one or more detectors 210 may be configured to “read” or detect themarker and provide that information to the controller 290 (e.g.,controller 90). The controller 290 may then be configured toautomatically control the various components of the manufacturingprocess 10 accordingly.

Depending on the desired configuration, some embodiments of the presentinvention contemplate different methods for obtaining information fromthe readable marker. For example, the readable marker may be a QR codeand cause automatic gathering of instructions for how the corrugatorshould operate based on following a link or other redirection methodprovided by the QR code. Similarly, other readable markers may cause thecontroller 290 to use a look-up table or other correlation means todetermine how to operate the corrugator. In some embodiments, the markermay include instructions in the marker itself. For example, positioncoordinates corresponding to a desired position for one or more knivesof a corrugator may form part of the marker. In such embodiments, thereis no need for a look-up table.

Example Control Plan Generation System(s)

FIG. 4A shows a block diagram of an example paper, sheet, and/or boxmanufacturing system 450. In the depicted example system 450, customers(e.g., Customer 1 451 a, Customer 2 451 b, and Customer 3 451 c) maysubmit orders to an Order Module 453 (such as described herein). TheImposition Engine Module 452 may communicate with the Order Module 453and a Resource Database 454, such as to enable generation of a controlplan (such as described herein). The Imposition Engine Module 452 mayalso communicate with one or more systems of the manufacturing process,such as to gather information/feedback and/or provide instructions(e.g., the control plan or portions thereof). For example, theImposition Engine Module 452 may communicate with a Press 1 455, a SheetProcessing/Formation System 1 456, an in-line manufacturing system 457(that includes a Press 2 457 a and a Sheet Processing/Formation System 2457 b), and other Manufacturing Systems 459.

Some embodiments of the present invention provide systems (such as auser interface, including for example a graphical user interface) forgenerating a control plan for a roll of web product for controllingmanufacturing of a paper-based product. Although some of the followingdescribed examples detail user generated input and/or overall controlplan generation by a user, some embodiments of the present inventioncontemplate automated generation and/or input as well. In someembodiments, one or more controllers and/or other hardware or softwaredescribed herein (e.g., controller 90, 590, 790, 890, 990, components ofthe phases in the described manufacturing processes 10, 510, 710, 810,910, and/or modules present in the described platform 100) may performvarious functions of the system.

FIG. 4B shows an example block diagram of control architecture forvarious example embodiments of the system 400 for generating a controlplan for a roll of web product for controlling manufacturing of apaper-based product. The control architecture of the system 400comprises cloud-based components 410 and intranet-based components 415,although some embodiments of the present invention contemplate any ofthe architecture being performed in the cloud and/or intranet.

The cloud-based components 410 include a web application (app) 412, aweb API (application program interface) 430, authorization architecture422, app database 440, app telemetry 425, and dashboards 420. Theintranet-based components 415 include orders architecture 460, resourcesarchitecture 470, and presses 480 (although additional/different systemsof the manufacturing process are also contemplated, such as describedherein).

A user may interact with the dashboards 420, such as to generate one ormore control plans for a roll of web product (such as described herein).In this regard, the dashboards 420 may be configured to receiveinformation (e.g., the control plan generation interface) from the webAPI 430, such as through the app telemetry 425. The web API 430 may beconfigured to check the user's authorization, such as through theauthorization architecture 422.

The web API 430 may be configured to gather available orders from theorders architecture 460. Additionally, the web API 430 may be configuredto gather order information from various components, such as the ordersarchitecture 460, the resources architecture 470, and/or the appdatabase 440. In this regard, orders for paper-based products may bereceived and/or stored in the orders architecture 460. Additionally,further information regarding the orders and/or various systems for themanufacturing process may be stored in the resources architecture 470and/or app database 440. In some embodiments, the various manufacturingsystems (e.g., presses 480) may be configured to store furtherinformation for completing the manufacturing process.

With order information and the available orders gathered, the web API430 may be configured to communicate and/or utilize the web app 412 toprovide an interface for a user to generate a control plan. Once thecontrol plan is formed, the web API 430/web app 412 may be configured tocommunicate the control plan or a portion thereof with various systemsof the manufacturing process, such as the presses 480.

FIGS. 5-16 illustrate an example process flow using an interface 300 forgenerating a control plan for a roll of web product, such as accordingto various example embodiments of systems described herein.

In some embodiments, the system may be configured to receive a requestfor generation of a control plan associated with a roll of web productfor manufacturing one or more paper-based products. For example, a usermay initiate a control plan generation procedure using one or moredashboards (e.g., graphical user interfaces).

In some embodiments, the request may include at least one criteria thatis used to identify orders for possible inclusion in the control plan.For example, the criteria for the request may include an indication of adesired width of the roll of web product and/or an indication of anavailable printer, sheet formation/processing system, and/or finishingsystem for use during manufacturing (e.g., an available press,corrugator, finishing system, etc.). In this regard, in someembodiments, the printer, sheet formation/processing system, and/orfinishing system may each be configured to process a maximum width forthe roll of web product. Based on such criteria, the system may returnavailable orders for selection, where the orders are able to fit withineither the desired width indicated or the maximum width allowed (e.g.,from the manufacturing system) depending on the indicated criteria withthe request.

FIG. 5 illustrates an example initial request screen 310 for initiatinga request to generate a control plan using the interface 300. On theinitial request screen 310, a side bar menu 305 may indicate home screenoptions and/or user information. For example, there may be an option togenerate a new control plan 305 a. The side bar menu 305 may alsoindicate the current user 305 b.

A user may enter an asset (e.g., a system used during the manufacturingprocess, such as a printer) at input 312. In the depicted embodiment,the user has used a drop-down menu that shows two options “Asset 1” 313a or Asset 2″ 313 b. As described herein, each asset may have differentlimitations or features that may be used by the system to determinewhich orders can be processed using that asset. Additionally oralternatively, the system may determine one or more componentconfigurations that can be used based on what asset is chosen. Forexample, Asset 1 313 a may enable processing (e.g., printing,corrugation, editing, etc.) on paper up to a certain width (e.g., 60″),whereas Asset 2 313 b may enable processing (e.g., printing,corrugation, editing, etc.) on paper up to a certain different width(e.g., 102″). In some embodiments, other component configurations may beaffected. For example, Asset 1 313 a may only allow one order to beprocessed due to limited functionality of a sheet formation/processingsystem (e.g., the corresponding corrugator may only enable one lane forprocessing). Asset 2 313 b may allow more than one order to be processedby a sheet formation/processing system (e.g., the correspondingcorrugator may enable multi-lane processing). Although the abovedescription details paper width and lane restrictions, other componentconfigurations may be used by the system for filtering orders and/orallowing generation of a control plan (e.g., color profiles, customerdesires, locations, printing capabilities, finishing systemcapabilities, upcoming deadlines, among many others).

In the depicted embodiment, a user may then enter a specific paperwidth, such as using line 314. A drop-down menu may also be employed. Insome embodiments, selection of the asset may filter available paperwidth options for a drop-down menu (e.g., the selected asset may only beable to process certain widths of paper). As shown in FIG. 6, a user hasselected Asset 2 313 b. In response, the drop-down menu 315 forselection of the paper width 314 has been updated to enable selection ofpaper widths that work with Asset 2 313 b. In some embodiments, theavailable paper widths that are presented could be based on otherfactors, such as cost, inventory availability, among other things.

Although the above example details entering an asset and then a paperwidth, in some embodiments, only one of the asset or the paper width maybe used to filter available orders for generating a control plan.Likewise, though some of the following description details additionalsearching for available orders, such criteria (alone or in variouscombinations) may be applied in addition to or in the alternative to theasset and/or paper width.

In some embodiments, the available orders may be searched and/orfiltered using other criteria. For example, such criteria may includejob type characteristics (e.g., sheet formation/processing system touse, paper type, additional material type being used (e.g., flutematerial), coating type, medium type, liner type, etc.), order number,and/or customer. By utilizing one or more such criteria, the number oforders presented for use in generation of the control plan can bereduced and/or highlighted for the user.

FIG. 7 illustrates an example order search/request screen 320 forgenerating a control plan using the interface 300. The search/requestscreen 320 provides a top menu with an indication of the selected asset316 and paper width 317. Additionally, the search/request screen 320includes three options for searching for orders (although someembodiments contemplate combinations of the options being used forfurther customized searching). A user may search using job typecharacteristics using the “Select Job Type” search 322. Under thatoption, a user may enter (e.g., add text or select from a drop-downmenu) a sheet formation/processing system (e.g., a corrugator) at 322 a,a paper type at 322 b, a flute at 322 c, a coating 322 d, a medium 322e, and/or a liner 322 f. For a second option, a user may search using anorder number using the “Select Job Type from Order” search 324. Underthat option, a user may enter (e.g., add text or select from a drop-downmenu) an order number. As shown in the depicted embodiment, as the userenters text, the drop-down menu 325 is filtered to match the enteredtext. For a third option, a user may search using a customer name usingthe “Select Job Type By Customer” search 326. Under that option, a usermay enter (e.g., add text or select from a drop-down menu) a customer,such as from the drop-down menu 327.

In some embodiments, the system may utilize one or more criteria(including any of the above described criteria as well as other criteriasuch as deadlines, cost, color profiles, maintenance schedule/issues,location of assets, etc.) to form recommendations for available ordersfor the user to add in generation of the control plan.

In some embodiments, the system is configured to provide one or moreavailable orders for paper-based products for selection by the user toform the control plan. In some embodiments, each of the available ordersfor selection may satisfy one or more criteria entered by the user (suchas described above). As detailed herein, the criteria may be checkedagainst order information associated with each order. For example, thecriteria may be used to filter among a plurality of orders that havebeen aggregated in one or more databases. In this regard, the orderinformation for each order may comprise information related tocompleting manufacturing of a desired product associated with the order.As detailed further herein, the order information may be gathered from aplurality of discrete systems.

FIG. 8 illustrates an example add order screen 330 for generating acontrol plan using the interface 300. The add order screen 330 providesone or more available orders 338 to add to the control plan, such asusing the green plus icon 339. In the depicted embodiment, additionalavailable orders to add may be “hidden” below the first available orderand accessible, such as by scrolling down the interface page.

In some embodiments, the system may be configured to show some orderinformation associated with the available order, such as may enable auser to make an informed selection. For example, the available order 338includes an order ID, a description, an asset planned for use, acustomer, a specific corrugator planned for use, a paper type, a paperwidth requirement, a processing set requirement (e.g., an “N-UP”number), a paper length, a product type, a coating, a flute type, aliner type, a medium type, and a total number of product (e.g.,“EACHES”) requested. As noted herein, such order information may begathered from any number of systems.

In some embodiments, the system may be configured to determine if anorder is “ready” for proceeding to the manufacturing process. Forexample, the system may determine if all necessary order information isavailable. Additionally or alternatively, the determination of whetheran order is ready for manufacturing may be based on available materials,systems, documentation, etc. In the depicted embodiment, the green plusicon 339 may provide an indication of the order being ready. Incontrast, the icon may present a different color or graphic when theorder is not ready for proceeding, such as the yellow icon 339′ with aline through a document shown in FIG. 10. Such an icon may indicate thatadditional information or actions are required prior to that order beingconsidered ready for processing. In such a regard, a user can be awareof whether an order is ready to begin manufacturing before adding it toa control plan.

The depicted add order screen 330 may also include a furthersearch/filter function 332. In this regard, the function 332 may bepresented as a separate box with prior entered search terms “Flutes”,“Coated 33#”, and “Uncoated 26#” indicating that the currently presentedorders have matching order information. The user may enter additionalorder information to filter/search by in line 334. Further, an icon withthe text “Width less than 96.50″” 336 may be presented, providing theuser knowledge of the remaining amount of paper width available for thecontrol plan. The presented available orders may be able to fit withinsuch a paper width.

FIG. 9A illustrates an example pop-up window 331 for the interface 300.In the depicted embodiment, the pop-up window 331 was generated uponselection of the available order 338. The pop-up window 331 indicatesthat the quantity of product planned for production (e.g., the “EACHES”)was updated to add 2 more units. To explain, some orders require acertain processing arrangement for the products as they are manufacturedthrough the various systems. For example, the order may produce a sheetor box structure (e.g., structure “C” 293 in FIG. 3A). However, theorder may require three structures of “C” to be processed together toform a processing set of sheet or box structures. With three structurestogether, the processing set would be “N-UP 3”. However, if the totalnumber of desired products (e.g., sheet or box structures) is notdivisible in whole by the N-UP number, then the system may be configuredto update the overall quantity to ensure that the total desired numberof products are manufactured. For example, the order 338 calls for 4840units, but the N-UP 3 can produce either 4839 (divisible by 3) or 4842(divisible by 3). In order to reach 4840 units, the system determinesthe need to produce 4842 units (e.g., 2 extra units).

In some embodiments, a user of the system may change the orientation ofa box structure outline for the order. In this regard, in someembodiments, the box structure outline may have a rectangular or othershape with different general length vs. width. For example, withreference to FIG. 9B, the planned box structure outline “A” 391 may havea different length 391 a vs. width 391 b. In such a regard, it may bedesirable to select which orientation the box structure outline 391 ison the web 390 in order to optimize the layout of the control plan. Forexample, the extra space 392 below the box structure outlines “A” 391 inFIG. 9B may not allow for another order to be added to the planned web390. As such, the user may determine that the orientation of the boxstructure outline should change such that the length 391 a of the boxstructure outline 391 is parallel with the length direction of the web390, such as shown as box structure outline 391′ in FIG. 9C. Thus, theremay now be more extra space 392′ below the box structure outline “A”391′, thereby enabling more orders to be positioned on the web 390.

Once a selection of an order is received, the system may be configuredto update the proposed control plan. In some embodiments, the system mayprovide a visual representation of the control plan, such as to aid theuser in generation of the control plan. For example, FIG. 10 illustratesan example screen 340 for the interface 300 that includes a visualrepresentation 345 of the control plan. The control plan 345 currentlyincludes one order 345 b and two web weaves 345 a, 345 c. The web weaves345 a, 345 c may be positioned on the width ends of the roll of printedweb product such as to enable processing through the variousmanufacturing systems. In some embodiments, the system may be configuredto determine and include one or more web weaves in the control plan. Inthe depicted embodiment, the web weaves 345 a, 345 c are 0.75″, althoughany size web weave is contemplated.

As noted above, the visual representation of the control plan 345 mayalso show a representation 345 b of the recently selected order 338(from FIG. 8). For example, the order 345 b may be presented in aprocessing lane (e.g., “2”) and include order information, such as adescription, order number, paper width requirement (e.g., “26.5″”), alength requirement (e.g., “7,515.19″”), a number of ribbons, and anumber of total produced product. In addition, the depicted embodimentprovides a waste width 342 and one or more functions (e.g., “ViewPreview” 346, “Confirm MLPA” 347, “Optimize Up” 348, and “Optimize Down”349), such as is described in further detail herein.

In some embodiments, the system may be configured to determine an amountof waste on the roll of web product for the control plan based on thecurrently selected orders. For example, the waste may be based on theamount of extra space remaining in the width direction on the selectedpaper width. For example, FIG. 10 shows a waste width of 70.00″, whichequals the 98″ of the selected paper width minus the total width 1.5″ ofweb weaves 345 a, 345 c and the width 26.50″ of the order 345 b. In theexample embodiment, the system has also calculated the percentage ofwaste as 71.4% and provided the indication of the amount to the user at342.

In some embodiments, the system may be configured to determine if theamount of waste satisfies an acceptable waste threshold and provide anindication as to whether the amount of waste satisfies the acceptablewaste threshold. For example, the system may determine an acceptablewaste threshold of 4% and once reached, provide such an indication tothe user. Similarly, in some embodiments, the system may be configuredto determine if the amount of waste satisfies an acceptable wastethreshold and prevent generation of the control plan in an instance inwhich the amount of waste does not satisfy the acceptable wastethreshold. For example, if the acceptable waste threshold is 4%, thenthe system at FIG. 10 may prevent finalizing the control plan until thewaste is sufficiently reduced (e.g., by adding more orders, splittingthe one or more selected orders to multiple ribbons, changing theoverall paper width, etc.).

In some embodiments, the system may provide one or more additionalavailable orders for selection. In some embodiments, like the firstavailable orders, the second available orders may satisfy certaincriteria. In some embodiments, the system may indicate one or moreavailable orders as recommended orders. In addition to or in alternativeto using the previously indicated criteria, the system may take intoaccount order information from the one or more currently selected ordersin the control plan. For example, available orders with similar job typecharacteristics may be recommended (e.g., highlighted, put at the top ofthe list, etc.). FIG. 10 illustrates two example available orders 344 aand 344 b. As detailed herein, order 344 a is not yet ready forprocessing and, thus, has a yellow icon 339′, whereas order 344 b has agreen icon since it is ready for processing. For the described exampleherein, the user selects the order 344 b for adding to the control plan.

In some embodiments, the system may be configured to determine that anavailable printer, sheet formation/processing system (e.g., corrugator),and/or finishing system planned for use with the roll of web product canaccommodate a plurality of lanes, such as prior to providing the secondplurality of available orders for selection. For example, the selectedasset (e.g., Asset 2 and/or a planned sheet formation/processing system)may be configured to allow multiple lanes of production. In such aregard, the system may be configured to determine such an ability andprovide additional available orders to add/apply to the available one ormore lanes.

FIG. 11 illustrates another example add order screen 350 for theinterface 300. Notably, the add order screen 350 includes a visualrepresentation 345′ of the control plan that now includes the firstselected order 345 a′ (in lane 2) and the second selected order 345 b′(in lane 3). Since the second selected order 345 b′ added an order witha width of 29.687″, the waste width 342′ has been updated to 40.313″(41.1%).

With additional waste width remaining, the system has presented anadditional search/filter function 352 where the user entered “1036” foran order number. Accordingly, 5 orders were found, one of which is order358. Notably, order 358 is presented with a red icon 339″ indicatingthat a user is unable to add it to the order 358. In this regard, one ormore rules may not be satisfied by order 358. For example, thecorrugator that is planned for use may only have two knives, allowingonly two lanes of orders to be processed. Instead of or in addition toentering the order number, the user may select the icon 356 that willfilter the remaining orders by those that have widths of less than40.313″ (e.g., the waste width).

With reference to FIG. 11, the second order 345 b′ has a length of12,150.42″, but the first order 345 a′ only has a length of 7,515.19″.This situation would result in waste being run on lane 2 while theremainder of lane 3 was being processed. To explain, the first order 345a′ (in lane 2) would complete prior to the second order 345 b′ (in lane3), but the roll of web product would still run with nothing in the lane2 area after the first order 345 a′ completed. The system may beconfigured to determine such waste and provide an indication and/or acorresponding recommendation to the user.

In some embodiments, the system may be configured to enable splitting ofan order into one or more ribbons so that the images print side-by-side.Depending on the desired length for the control plan, this feature maybe used to minimize waste. For example, FIG. 12 illustrates an updatedcontrol plan 345″, where the user has changed the second order to 2ribbons, decreasing the overall length down to 6,075.21″. Additionally,however, the width used by the second order was increased to 59.374″,which also reduced the waste width 342″ to 10.626″ (10.8%).

Though the above example describes adding a ribbon, other changes can bemade during generation of the control plan to affect the waste widthand/or length, such as adding another order, changing the number ofdesired products (EACHES), changing the length of the order, etc.

In some embodiments, the system may be configured to adjust the overallpaper width for the control plan, such as to account for and/or reducethe waste width. In some embodiments, the system may be configured to,in response to receiving a selection of an order, provide a suggestedwidth for the roll of web product to minimize a remaining unused widthof the roll of web product that is available after including one or moreselected orders. In some embodiments, the system may have anauto-optimize paper width feature that automatically selects therecommended paper width to reduce waste width. As an example, withreference to FIG. 13, a user has selected a drop-down menu for theoverall paper width 317 and selects 90″. In the depicted embodiment, thesystem has highlighted 90″ for selection, such as providing arecommendation (e.g., to reduce waste width). Accordingly, FIG. 14illustrates that the waste width 342′″ has been updated to 2.626″(2.9%).

In some embodiments, the system may be configured to enable usage of anoptimization up/down feature. In some embodiments, the optimization upor down function may enable the overall number of products for at leastone of the selected orders to be reduced or increased in order to causean overall length of the roll of web product being used for the selectedfirst order to better align with an overall length of the roll of webproduct being used for the selected second order (and other selectedorders if applicable). In some embodiments, the system may be configuredto automatically determine which order to optimize and which direction(e.g., up or down) to optimize based on one or more factors, such as acustomer's willingness to receive extra product, the printercapabilities, among other things. In some embodiments, as describedherein, some customer orders may enable a certain of percentage ofproduct over the requested amount to be provided under the contract.Using such information, the optimization up or down function may be usedto further reduce waste (e.g., in the length direction of the roll ofweb product).

FIG. 15 illustrates an optimization up/down feature for the interface300. With reference to FIG. 14, the first order (lane 2) has a length of7,515.19″, whereas the second order (lane 3) has a length of 6,075.21″.A user may use the optimize up/down function, such as by selecting the“Optimize Up” icon 348 in FIG. 15, to further reduce waste in the lengthdirection. By selecting the “Optimize Up” icon 348, the total number ofproduct for the second order (lane 3) increased to 5984 units (from 4840units) and the overall length increased to 7,511.17″. Thus, the newoverall length for the second order (lane 3) is very close to theoverall length 7,515,29″ of the first order (lane 2), thereby minimizingwaste in the length direction.

In some embodiments, the system may be configured to enable a preview ofthe roll of web product after printing for the proposed control plan.For example, a user may select the “View Preview” icon 346 shown in FIG.10. In response, and based on the proposed control plan 345″″ of FIG.15, the corresponding preview 370 shown in FIG. 16A may be presented.The preview 370 may include visual representations after printing of theweb weaves 371, 375, the first order 372 (lane 2), and the second ordersplit into two ribbons 373, 374 (lane 3).

In some embodiments, the system may be configured to confirm accuracy ofthe generated control plan. For example, the system may check theproposed control plan against one or more rules or thresholds todetermine acceptability of the proposed control plan. Such a functionmay be initiated in response to selecting, for example, the “ConfirmMLPA” icon 347 shown in FIG. 10.

In some embodiments, the system may be configured to finalize, generate,and/or save the proposed control plan. In some embodiments, the proposedcontrol plan may be presented in a review mode or screen for the user toeasily determine/approve the proposed control plan. Once finalized, thecontrol plan may be saved with a custom name, such as to a database.Additionally, in some embodiments, such as described herein in greaterdetail, all necessary information may be gathered and all necessaryformats may be generated for controlling operation of the variousmanufacturing systems. Thereafter, the control plan may be implementedto control manufacturing accordingly.

In some embodiments, the system may be configured to generate a labelbased on the control plan. In some such example embodiments, the labelmay be printed and applied to the physical roll of web product (e.g., toan end of the roll of web product, a casing for the roll of web product,etc.). In some embodiments, the label may include at least one computerreadable marking that, upon being read, either identifies the controlplan or supplies the control plan to the detector system/manufacturingsystem intended for use. In some embodiments, the label may includeinformation about the control plan or various orders within the controlplan. In some embodiments, the label may include a preview of theprinted roll of web product, such as may be useful for visualconfirmation by one or more operators.

As detailed herein, some example embodiments of the system enablefiltering, searching, and/or recommendations of available orders basedon criteria. In this regard, some example embodiments of the presentinvention are configured to determine order information about eachavailable order to use for generation of the control plan. Such orderinformation may also be formed as part of the control plan and used byvarious manufacturing systems, as well as other functions describedherein. By pulling all the information together, the system can performmultiple functions that provide for an efficient manufacturing process.

In this regard, in some embodiments, the system is configured to gatherorder information from a plurality of discrete systems. For example, thesystem may pull order information about an order from a graphicsplanning system, a management information system, a sheetformation/processing planning system, and/or any other modules/systemsdescribed herein (such as in the platform 100). In this regard, onebenefit of the system is that it can gather all necessary orderinformation for performing the various functions described herein,including forming detailed/acceptable instructions for the varioussystems used during the manufacturing process—such as for generation ofthe control plan. For example, the system may be configured to form aset of printing instructions to enable operation of the printeraccording to the control plan, where the set of printing instructionsare formed into a format that is acceptable to the printer. In thisregard, the printer may only accept a certain file format and may needinformation that comes from different discrete systems. As such, thesystem may be configured to prepare the needed format (e.g., JMF/JDF)and provide it to the printer to operate according to the control plan.Likewise, the system may be configured to form a set of sheetformation/processing instructions to enable operation of the sheetformation/processing system according to the control plan, where the setof sheet formation/processing instructions are formed into a format thatis acceptable to the sheet formation/processing system. Similarly, insome embodiments, the system may be configured to form a set of visionsystem instructions to enable operation of the vision system, such as toconfirm a desired accuracy of one or more images from the printer (e.g.,using one or more golden images).

In some embodiments, the system may be configured to instruct thevarious manufacturing systems according to the control plan. In someembodiments, the system may, for example, be configured to instruct theprinter to perform various operations that may otherwise be manuallyrun. For example, in addition to causing the printer to use certaincolor profiles, inks, etc., the printing instructions may cause theprinter to perform one or more test jobs, stress jobs (e.g., to test theprint heads), calibration jobs, and/or prepare one or more golden imagesthat may be later used for quality checks. In some embodiments, thegolden image may be formed prior to the production run, such as at thebeginning of the roll. In some embodiments, the golden image may beformed after the product run, such as at the end of the roll.

In some embodiments, the system may be configured to run a stress jobfor one or more presses of the system. In some embodiments, the stressjob may be automated, such as based on a determination that one or moreprint heads of the press have not been operating (e.g., beenunutilized). For example, with reference to FIG. 16B, a press 398 may beprinting on a web 390′ (e.g., the web 390′ may be running in the “PD”direction). The press 398 may be printing with respect to planned boxstructure outlines “A” 391 and “B” 393 utilizing a certain number ofprint heads (e.g., print heads PH₂-PH₆). Notably, however, the press 398may not be utilizing some of the print heads (e.g., print heads PH₁ andPH₇), such as due to extra space being above 396 a and/or below 396 bthe planned box structure outlines. In such a scenario, it may bedesirable to perform a stress test for the unused print heads for one ormore upcoming orders where they may be utilized (e.g., for planned boxstructure outlines “C” 394 and “D” 395). In some embodiments, the systemmay determine that such previously unused print heads will be needed foran upcoming order and cause a stress job to be run by the press to getthe previously unused print heads ready for printing. In this manner,unnecessary poor image quality may be avoided. Such an automated stressjob may be determined based on various factors/circumstances, such as ifthe print heads have not been operating for a certain amount of time,after every order, or other factors. In some embodiments, the system maycause the stress job to be performed in between orders, such as in space399 on the web 390′. This may maintain efficient flow of the web 390′and utilize already planned waste.

Some visions systems may utilize one or more golden images to confirmthat the printed image/images on the printed roll of web product areacceptable. In this regard, in some cases, a vision system may compareeach printed image to a reference golden image and determine whether theprinted image satisfies a golden image tolerance threshold. Such agolden image tolerance threshold may be based on any number of factors,such as color degree, an amount of blanks or white space, other defects,etc. In some embodiments, the tolerance threshold for verifying someprinted images may be greater than others. For example, a customer mayprefer that the printed images match the desired image very closely, andmay perhaps be willing to pay a premium. Likewise, some customers may bewilling to accept a higher degree of variation, such as in favor ofother considerations (e.g., price, speed, delivery date, etc.).Moreover, some portions of the order may have different tolerance levels(e.g., different printed images within the same order may have differenttolerance level). For example, maintaining the proper degree of “red” ina cola product may be important, but the color level of “white” for thewriting on the same box may be less important.

In some embodiments, the tolerance level of each order may be saved withthe order information and utilized (such as in conjunction with thegeneration of the control plan and/or scheduling production runs). Forexample, the system may determine that the print head quality of theprinter is better during a certain time period (e.g., right aftercleaning), and may recommend performing a production run or generationof a control plan so that an order with a lower tolerance level is runat the most opportune time. Similarly, the system may recommendaggregating orders together when generating a control plan to matchsimilar tolerance levels. In such an example, editing needs may besimilar across the width of the printed roll, which may limit the needfor splicing and editing of one side of the printed roll when the otherside doesn't need it (e.g., the other side has a higher tolerancelevel).

Some visions systems and printers may be configured to work together toform or generate a golden image. In this regard, in some embodiments,the printer may be instructed to dynamically create a golden image. Asalluded to above, it is important to generate a proper golden image thatcan be used as an accurate reference point. As such, some printers maybe configured to generate a golden image at the beginning of aproduction run, under the assumption that the printer was justcleaned/serviced, etc. However, in some embodiments, in order tomaintain efficient printing/manufacturing, it may be desirable to notstop and clean/service the printer between production runs. In such acase, preparing a “dynamically” created golden image may cause a lessthan ideal golden reference image to be formed—meaning that the “goldenimage” has its own defects or may not be in a best-state. This may leadto undesirable results when attempting to verify printed images usingthe less desirable golden image.

In some embodiments, the system may be configured to store and save oneor more golden images for an order. In such an example embodiment, theone or more stored golden images can be provided to the printer/visionsystem for utilization. Further, such a golden image may be confirmed tobe a “best-state” golden image such that the printer was in thebest-state when created. In some embodiments, the customer may provideor select the golden image for an order. Further, such a saved goldenimage may be useful for future similar or repeat orders. This maintainsaccurate image production by using a best-state golden image andmaintains efficiency by removing the need to clean/service the printerbetween orders. Further efficiency may include being able to rely onprior golden images—thereby removing the need to create new goldenimages.

In some embodiments, the system may be configured to instruct theprinter when to create the golden images. For example, the system mayinstruct the printer to perform a golden image creation run where one ormore golden images are created and saved. In this regard, the goldenimage creation run may be performed at an ideal time, such as after theprinter has been cleaned/serviced. In some embodiments, such a goldenimage creation run may create multiple different golden images (e.g.,from different orders) to further maximize efficiency.

Though the above description details a golden image creation run, insome embodiments, the system may be configured to instruct the printerto dynamically create a golden image, such as in conjunction with aproduction run for an order. In such an example, the golden image may beformed at some point in the order (e.g., beginning, middle, end, etc.).In some cases, the system may determine and instruct the printer as towhen to form the golden image such as in an effort to prepare abest-state golden image.

In some embodiments, the system may be configured to send the one ormore golden images for an order to the printer and/or vision system. Forexample, the golden image(s) may be sent to the printer along with theorder (e.g., generated control plan). In some embodiments, the goldenimage(s) may be sent to the vision system separately from the printer(such as in an XML file). In some embodiments, a hot folder may beformed in a database of the system and access thereto may be provided tothe printer and/or vision system to access/retrieve the golden imagetherefrom.

In some embodiments, as noted herein, the system may be configured toprepare a set of quality check instructions for operation of the visionsystem. In some embodiments, the set of quality check instructions mayinclude access to one or more golden images. Additionally, however, theset of quality check instructions may provide instructions on whichgolden images to utilize for which lane of a multi-lane printed web. Forexample, as described herein, multiple orders may be printed in thewidth direction of a roll (e.g., according to a control plan). In suchembodiments, the vision system may need to be instructed as to whichgolden images to utilize for which order (and where on the web theprinted images may be). Further, multiple ribbons may be printedside-by-side. In such a regard, in some cases, the same golden image canbe utilized across and down the printed roll (often called “step andrepeat”), or separate or different golden images may be needed. In someembodiments, golden images may be grouped together to help comparemultiple grouped printed images at the same time.

FIG. 16C shows four example different use cases for utilizing one ormore golden images during a quality check for a printed roll of webproduct in accordance with various example systems described herein.

Use Case 1 represents a printed roll of web product 380 with 3 of thesame printed images across (the width of) the web. In such an exampleuse case, the system may be configured to instruct the vision system toapply the same golden image (382 a) for each printed image across (e.g.,382 a, 382 b, 382 c) and down (e.g., 382 d) the printed roll of webproduct.

Use Case 2 represents a printed roll of web product 380′ with 3 of thesame printed images across (the width of) the web. In such an exampleuse case, the system may be configured to instruct the vision system toapply separate golden images (382 a′, 382 b′, 382 c′) for each laneacross (e.g., 382 a, 382 b, 382 c) the printed roll of web product.

Use Case 3 represents a printed roll of web product 380″ with threeprinted images across (the width of) the web, where one (382″) isdifferent than the other two (384″, 386″). In such an example use case,the system may be configured to instruct the vision system to apply afirst golden image (382″) for each printed image down the web in thefirst lane (e.g., the printed images following 382″ down the web), asecond golden image (384″) for each printed image down the web in thesecond lane (e.g., the printed images following 384″ down the web), anda third golden image (386″) for each printed image down the web in thethird lane (e.g., the printed images following 386″ down the web).

Use Case 4 represents a printed roll of web product 380′″ with threeprinted images across (the width of) the web, where one (382′″) isdifferent than the other two (384″, 386′″). In such an example use case,the system may be configured to instruct the vision system to apply afirst golden image (382′″) for each printed image down the web in thefirst lane (e.g., the printed images following 382′″ down the web).Additionally, the system may be configured to apply a group of goldenimages (e.g., 384″) for a corresponding group of printed images down theweb in the second lane (e.g., groupings of printed images following384′″ down the web). Likewise, the system may be configured to applyanother group of golden images (e.g., 386″) for a corresponding group ofprinted images down the web in the third lane (e.g., groupings ofprinted images following 386′″ down the web).

In some embodiments, each order in the vision system may be determinedby the system to link with a lane of a downstream sheetprocessing/formation system (such as a corrugator). In such exampleembodiments, the system may be configured to gather information from thevision system to determine how best to remove defective images on theprinted roll of web product. For example, in some embodiments, a reeleditor may be utilized to remove one or more portions of the printedroll of web product. This may include splicing the roll of web productor separating the roll of web product and splicing out or removing thedefective image.

In some cases, however, the control plan may include instructions toprocess the printed roll of web product through the sheetformation/processing system where there are multiple lanes of printedimages. In some such cases, one of the lanes may have a defective image,while the other lane(s) may not. It may be advantageous to not removethe defective image until the lanes are separated during sheetformation/processing (e.g., during use of the corrugator) such as topreserve the good images in the other lanes. In some embodiments, thesystem may be configured to determine the desirable approach andinstruct the operator/systems accordingly.

In some embodiments, the system may be configured to receive feedbackfrom the various manufacturing systems and learn/adapt for futureoperational efficiency. For example, the system may gather historicalinformation that may be linked to certain characteristics (e.g., orderinformation) for an order. Then, when forming a control plan with anorder that has a similar characteristic, the system may apply thathistorical information to adapt operation of the various manufacturingsystems (e.g., run a different type of stress job, run less thanexpected test jobs, etc.).

In this regard, in some embodiments, one or more characteristics of thepress or lanes on a press for specific orders may be saved/stored forfuture similar orders. For example, some customers may have colorprofiles that they wish to have on their orders (e.g., a specific colorred or a specific color green—such as may be associated with theirbrand). Depending on the substrate used for the order (e.g., paper type)the printing characteristics (e.g., color mixture, print head type,etc.) may need to be different in order to obtain the universallydesired specific color profile. Such information can be saved andutilized by the system when preparing a control plan for passing to aspecific press or manufacturing process/system. This would avoidunnecessary poor or undesirable image quality.

Along similar lines, in some embodiments, the system may be configuredto monitor and collect error messages received by various manufacturingsystems and their corresponding meaning and/or fix. For example, one ormore presses may present a press specific error message. After fixingthe error message, the system may save/store the error message forfuture understanding. Additionally, the system may save/store any fixesand apply them to future orders either on an as-needed basis orpre-emptively (such as by adapting a control plan to avoid the errorever occurring). Depending on the size of the system and the number orvariety of manufacturing systems, such a feature may be beneficial andhelp maintain efficient and effective operation.

In some embodiments, the system may enable an operator (e.g., scheduler,manufacturing system operator, etc.) to control and/or modify a que ofupcoming orders. In such an example embodiment, one or more operatorsmay control the order flow through the various manufacturing systems.This could be accomplished by an operator of the control plan generatoror by an operator specific to one or more manufacturing systems (e.g.,an operator of a corrugator and/or press). By allowing modification ofthe order que, the operator may take advantage of various circumstancesto help maintain efficiency. For example, a certain type of paper for alater order may already be installed and, thus, the operator may want to“jump” to that order.

In a similar manner, the system may take into account each plannedmanufacturing system that will be utilized for a control plan and modifythe control plan accordingly. In some embodiments, the modificationcould be performed after the control plan is sent to the manufacturingsystem, such as by an operator of the manufacturing system directly. Insome embodiments, a manufacturing system may have desired specificationsfor each control plan. For example, an example corrugator may have adesired distance between orders (e.g., 25 feet), such as to enablechanging of various features of the corrugator between orders. Such adesired distance may be different for other corrugators and, thus, thecontrol plan may be updated to account for the desired distance (amongother specifications). Such modifications could be accomplished on thefly as the control plan is being processed. Another examplespecification is the justification of the orders on the web. Forexample, it may be desirable to have the orders center justified (e.g.,versus left or right justified). Such a consideration could be importantfor matching the order with a coding mat that is pre-set to a certainjustification (e.g., center justified), however, other features may leadto a desired justification (e.g., location of mark detectors laterallyacross the web).

In some embodiments, the system may be configured to take into accountcurrent or planned inventory when generating a control plan or passing agenerated control plan to a manufacturing system for processing. Forexample, the system may gather inventory information (such as from theresource database 454 shown in FIG. 4A) and determine whether certaininventory (e.g., paper type, ink, etc.) is available to process thecontrol plan. In some embodiments, the location of the inventory may beutilized in determining where to send the control plan for processing(such as if there are multiple options). For example, one corrugatorlocation may have a certain paper type whereas another corrugatorlocation may not.

In some embodiments, the system is configured to track the status of themanufacturing process for the generated control plan. For example,feedback from various manufacturing systems, one or more read markings,and/or manual operator entries can be used for tracking the progress ofthe manufacturing process. In such a regard, in some embodiments, thesystem may be configured to provide order status to a customer. Forexample, the system may track the control plan through the manufacturingprocess and provide status updates in real-time, such as through acustomer dashboard. In some embodiments, knowledge of the available orplanned inventory and schedule of the control plan can be used toprovide estimated order completion dates, locations, or otherinformation.

Example Corrugated Box Manufacturing Process

Corrugated sheet and box manufacturing is an example paper, sheet,and/or box manufacturing system. In some such manufacturing, acorrugator (e.g., high speed laminator) is used to glue together layersof board web with a flute medium positioned in between. Depending on thedesired characteristics of the corrugate board web, differentlayers/arrangements can be combined. Once formed, the corrugate boardweb (e.g., top layer, flute medium, and bottom layer) may then be cutinto appropriate sheet or box structures, and later scored, cut, gluedetc. to form the broken down box (that is then folded and manipulated toform the box, such as by the customer). Although the followingdescription provides detailed examples of “corrugators”, some exampleembodiments of the present invention contemplate the term “corrugator”to mean a board-making device, such as a high speed laminator.

FIG. 17A illustrates an example corrugated box manufacturing process 510according to various embodiments of the present invention. Themanufacturing process 510 includes a number of phases that result in afinished corrugated sheet or box that is shaped and printed per thecustomer's order. The process 510 may include an ordering phase 512, aplanning phase 514, a print phase 530, a reel editor phase 540, a boardmaking/cutting phase 560 (e.g., a sheet formation/processing phase), afinishing phase 570, and a tracking/logistics phase 580. In someembodiments, less or more phases or different orders of phases arecontemplated. Additionally, while the described example is detailed forcorrugated box making, some embodiments of the present invention arecontemplated for extension into other product manufacturing, includingprinted paper-based product manufacturing, such as folded carton,beverage labels, flexible paper, industrial bags, plates, cups, décor,and many others.

In the ordering phase 512, a customer may supply an order that includesdesired characteristics for the end product. For example, the customermay provide a number of desired sheet or box structures, sheet or boxshape requirements, one or more images/designs for printing on the sheetor box, color specifications, among many others. In some embodiments,the customer 512 may input such an order through a web interface. Theweb interface may enable the customer 512 to easily input the desiredcharacteristics of the order electronically. The web interface may alsoenable the customer to perform many related tasks, including, forexample, updating orders, tracking orders, handling payment, requestingassistance, setting up automated ordering (e.g., recurring ordering),viewing and approving example images (“soft proofing”), viewing exampleend products, etc.

In addition to providing increased efficiency of process for thecustomer, the web interface may also directly interact with and provideinformation for automated processes useful in the remainder of themanufacturing process 510. For example, the information from the webinterface may be fed directly into a corrugator plan controller (such asthe controller 590) and utilized accordingly. For example, as describedherein, the information from the web interface may be used to form acorrugator plan and/or associated reel map or print plan of thecorrugated sheet or box structure making process. Additionally, however,the information from the web interface may be used to provide on-the-flyupdates or adjustments to the manufacturing process. Further, feedback(e.g., from the controller 590) may be provided back to the webinterface for the customer, such as tracking information, images of thecompleted sheet or box structures, among other things.

In some embodiments, a controller 590 may be configured to performvarious functionality useful in the manufacturing process 510 (e.g., thevarious modules/phases described herein). For example, the controller590 (such as during the planning phase 514) may be configured to form acorrugator plan (which may be included in an associated reel map), suchas may be used in conjunction with the corrugator 550 (e.g., during theboard making phase/cutting phase 560). As used herein, in someembodiments, an associated reel map may be an example of a corrugatorplan. In this regard, other example corrugator plans (e.g., a printplan) can be used, formed, etc. Additionally or alternatively, thecontroller 590 may be configured to form a print plan that is used inthe printing phase 530 (such as described herein). Likewise, thecontroller 590 may be used with the ordering phase 512, such as toreceive order information, the finishing phase 570, and/or thetracking/logistics phase 580. An example controller 590 is describedfurther herein as controller 690 (which is shown and described withrespect to FIGS. 18A and 18B). In some embodiments, the controller 590may be spread over any number of controllers at any of the variousphases of the manufacturing process 510.

In some embodiments, sections of the process flow can be shifted fromplant to plant or device to device due to various externalcircumstances. For example, repair of certain parts of the corrugator,replacing certain printer inks, etc., may cause only certain customersheet or box structures to be able to be manufactured. In this regard,in some embodiments, certain portions of the process flow may beshifted, such as being jumped in line, moved to another facility, etc.,in order to maintain efficient up time of operation of the printer(s)and corrugator(s).

The manufacturing process 510 may also include the printing phase 530,reel editor phase 540, and board making/cutting phase 560. In someembodiments, the printing phase 530, reel editor phase 540, and boardmaking/cutting phase 560 may be performed using a corrugator 550 (suchas shown in FIG. 17A) or other manufacturing system. Alternatively, insome embodiments the printing phase 530 and/or reel editor phase 540 maybe performed separately, prior to the corrugator 550′ (such as shown inthe manufacturing process 510′ shown in FIG. 17B). Similarly, FIG. 17Aalso illustrates that the real editor phase 540 may be optional within acorrugator 550 that also employs a printing phase 530. FIG. 18Aillustrates an example corrugator 650 that incorporates the printingphase 530, the reel editor phase 540, and the board making/cutting phase560 to form an in-line process. In some embodiments, the reel editorphase 540 may not be included in the example corrugator 650 of FIG. 18A.FIG. 18B illustrates an example corrugator 650′ with the printing phase530 and the reel editor phase 540 occurring separately, prior to theboard making/cutting phase 560. This approach is sometimes referred toas a near-line process.

With reference to FIG. 18A, the corrugator 650 may, such as throughcontroller 690, cause conveyance of one or more paper web, printed web,corrugated board web, and/or flute medium through the machine (andvarious phases), such as along the machine direction (MD) arrow. Forexample, one or more conveyor means (e.g., a conveyor belt) and/ormotors may be used to cause a top layer 622 of paper web to pass througha printing phase 630 and, optionally, a reel editor phase 640. The toplayer 622 of paper web may be held in a roll 621 (or other form), suchas may be referred to herein as a roll of web product. The corrugator650 may also control introduction of one or more flute mediums 629and/or other layers to form the corrugated board web (such as the roll623 of the bottom layer 624 of corrugated board web).

As described herein, in some embodiments, a reel map (e.g., a corrugatorplan) may be used to help maintain efficient operation of the corrugatorand avoid waste during making of the sheet or box structures. In thisregard, a certain arrangement of sheet or box structures may need to befollowed through the corrugator 650. Such operation and tracking mayoccur, such as through use of the controller 690.

As described in more detail herein, the controller 690 provides logicand control functionality used during operation of the corrugator 650and, in some embodiments, the entire manufacturing process 510. In someembodiments, the functionality of the controller 690 may be distributedto several controllers that each provides more limited functionality todiscrete portions of the operation of manufacturing process 510. In thisregard, the controller 690 may have the same or similar suitablehardware or software to the controller 90 described herein.

The controller 690 may be operably coupled with one or more componentsof the manufacturing process 510, including for example, the roll 621 ofthe top layer 622 of corrugated board web, a medium holder (e.g., roll)628 of medium 629, the roll 623 of the bottom layer 624 of corrugatedboard web, various components of the printing phase 630, variouscomponents of the reel editor phase 640, various components of theboarding making phase 645, various components of the cutting phase 660,conveyance means of the corrugator, various components of phases for themanufacturing process, and other components (such as described herein).For example, depending on the components, the controller 690 may beoperably coupled such as through use of solid-core wiring, twisted pairwiring, coaxial cable, fiber optic cable, mechanical, wireless, radio,infrared, etc. In this regard, depending on the components, the operablecoupling may be through one or more intermediate controllers ormechanical coupling, such as used for controlling some components (e.g.,controlling operation and/or feeding of the roll 621 of the corrugatedboard web). In some embodiments, the controller 690 may be configured toprovide one or more operating signals to these components and to receivedata from these components.

As noted above, the controller 690 (e.g., the corrugator plancontroller) may be split into more than one controller, such as multiplecontrollers that exchange information, data, instructions, etc. Forexample, the controller 690 may be split into a corrugator planningsoftware controller, a corrugator machine user interface controller, acorrugator system controls, press 630 operations and graphics workflowsoftware and/or specific functional controls (e.g., a separate visionsystem such as described herein).

In some embodiments, such as described in greater detail herein, thecontroller 690 may be operably coupled to one or more vision systems,such as for detecting markers and/or defects/errors during themanufacturing process. Depending on the feedback from the visionsystems, the controller 690 may control the corrugator 650 and/ormanufacturing process 510 accordingly.

Depending on the configuration of the corrugator, the printing phase 630may occur prior to combining the layers of corrugated board web 621, 623and flute medium 628 (e.g., “pre-print”) or after combining two or morelayers (e.g., “post-print”). In some embodiments, printing may occur toother layers (e.g., the bottom layer 623), such as in alternative to orin addition to the top layer 621.

During the printing phase 630, the controller 690 may direct the pressdigital front end (DFE) and raster image processor (RIP), etc., to printone or more images at specific locations on the top layer 622 of thepaper web. Depending on the configuration of the corrugator 650 and/ormanufacturing process 510, the controller 690 may utilize a process flow(e.g., reel map) to determine where on the paper web to print the imagesand/or markers. For example, an image selected by the customer (such asa bottle), may be printed in the center (or other section) of a sheet orbox structure—such as may ultimately be visible for marketing or otherpurposes once the box is formed. Any image (including, words, markers,instructions, etc.) are contemplated by various embodiments of thepresent invention. Example markers that can be printed, include anymarker that may be used by various components of the manufacturingprocess 510, such as for tracking, cutting, printing, etc. Furtherdescription regarding possible markers and their utilization is providedin greater detail herein. In this regard, the controller 690 may beconnected to one or more vision systems that are used to read or detectcolor, defects, and various markers for controlling and/or updatingoperation of the corrugator 650.

During the reel editor phase 640, the controller 690 may be configuredto perform functions described herein related to editing or determiningwhether to edit the printed top layer of board web. Although shownin-line, in some example embodiments, the reel editor 640 may be out ofline or near-line such that the roll of web product may be transferredto the reel editor 640 for processing. In some embodiments, thecorrugator may have one or more functions/features that enable editingof the roll of web product (such as removing waste). In some suchexample embodiments, the reel editor 640 may form part of thecorrugator.

During the board making phase 645, the controller 690 may be configuredto cause combining of one or more layers and/or flute medium to form thecorrugated board web for the boxes. For example, the controller 690 maybe configured to cause fluted medium 629 to be fed into contact with oneor more layers of corrugated board web, such as between a top layer 622(such as from the roll 621) and a bottom layer 624 (such as from theroll 623). In this regard, in some embodiments, the fluted medium 629may be fed into contact with the top layer 622 prior to the combinedfluted medium 629 and top layer 622 coming into contact with the bottomlayer 624. The controller 690 may cause formation of the combined layersinto a layered corrugated board web 620, such as through use of glue orother adhesive.

During a corrugator editing phase 649, the controller 690 may beconfigured to edit the corrugated board web, such as by chopping outwaste or undesirable corrugated board web. Such waste can be removedfrom the corrugator 650.

During the cutting phase 660, the controller 690 may be configured tocut out the sheet or box structures. In this regard, the controller 690may be operably coupled to the various knives to control operationduring the cutting phase 660. In some embodiments, the controller 690may be configured to utilize the process flow (e.g., reel map) todetermine how to operate the various knives (e.g., move the knives,cause a cut to occur, etc.).

FIG. 19 shows an example cutting phase 660 that includes a knife (e.g.,slitter 664) that is configured to cut the layered corrugated board web620 in the longitudinal (or machine) direction. The cutting phase 660also includes two knives 666, 667 that are each configured to cut thelayered corrugated board web 620 in the lateral direction or crossdirection CD. As described herein, the controller 690 may be operablycoupled to the various knives to control operation thereof. In someembodiments, the controller 690 may be configured to utilize the processflow (e.g., reel map) to determine how to operate the various knives(e.g., move the knives, cause a cut to occur, etc.).

As the layered corrugated board web 620 passes through the cuttingphase, a slitter 664 may be configured to split the layered corrugatedboard web 620 to cause it to split into different sections that travelon different paths (such as the top section 626 that travels along thetop path and the bottom section 627 that travels along the bottom path).In some embodiments, a first sheet or box structure may form the topsection 626 and a second sheet or box structure may form the bottomsection 627—thereby creating two different paths that separate the twotypes of sheet or box structures (e.g., sheet or box structure A, 691 isformed in the top section 626 and sheet or box structure B, 692 isformed in the bottom section 627). The location 665 in which the slitter664 performs the cut is important because sheet or box structures mayvary as the layered corrugated board web 620 travels through thecorrugator. For example, FIG. 3A shows that a slitter would need to cutat a first position P₁ to cause separation of the sheet or boxstructures A, 691 from the sheet or box structures B, 692. However, theslitter would need move at the right time (e.g., the transition from thesheet or box structures A, B to the sheet or box structures C, D) or asecond slitter may be used to cut instead at the second position P2 tocause separation of the sheet or box structures C, 693 from the sheet orbox structures D, 694. Referring back to FIG. 8, the slitter 664 may bemovable (such as based on instruction from the controller 690) in thecross direction CD in order to cut the layered corrugated board web 620at the proper position.

Once separated into different paths, the various sections of layeredcorrugated board web 626, 627 may pass through respective knives 666,667. In some embodiments, the knives 666, 667 may be configured (such asbased on instruction from the controller 690) to cut the sheet or boxstructures in the lateral (cross) direction in order to form the desiredsheet or box structures. For example, knife 666 cut the top section 626to form the sheet or box structures A, 696. Likewise, knife 667 cut thebottom section 627 to form the sheet or box structures B, 697.

In some embodiments, other knives may be utilized for cuts, such as sideslitters for cutting scrap along the edges. Likewise, other componentsmay be utilized, such as scorers for pre-creasing sheet or boxstructures. Such other knives and/or components may be formed as part ofthe above described systems.

Referring back to FIG. 17A, with the sheet or box structures cut, themanufacturing process 510 may continue to the finishing phase 570. Thefinishing phase 570 may include additional printing, additional cutting,additional gluing, and/or other necessary functions to achieve afinished sheet or box structure for sending to the customer. In someembodiments, a vision system or other visual inspection system may beused to confirm accuracy of the order.

The manufacturing process 510 may also include a tracking/logisticsphase 580 that includes tracking the finished sheet or box structuresand preparing/delivering them to the customer. In some embodiments, oneor more tracking or counting systems can be implemented upstream in themanufacturing process 510, such as to enable tracking/logistic planning(including separating orders) throughout the manufacturing process 510.

Example Other Product Manufacturing Processes

As noted herein, some embodiments contemplate systems for controllingmanufacturing of various products, such as various paper-based products,including corrugated boxes, folded carton, labels, flexible paper,industrial bags, plates, cups, décor, and many others. FIGS. 20-23illustrate block diagrams of various example other paper-based productmanufacturing contemplated by various embodiments described herein. Inthis regard, some embodiments of the present invention contemplate oneor more controllers (e.g., controller 90) that can generate and providea control plan to various devices/systems for performing efficientmanufacturing of such various products.

FIG. 20 shows a block diagram of an example folded carton manufacturingprocess according to various embodiments of the present invention. Themanufacturing process 710 includes a number of phases that result in afinished folded carton that is shaped, formed, and printed per thecustomer's order. The process 710 may include an ordering phase 712, aplanning phase 714, a print phase 730, a reel editor phase 740, a sheetformation/processing phase 760, a finishing phase 770, and atracking/logistics phase 780. Such phases may be similar to the phasesdescribed with respect to the manufacturing phase 10 of FIG. 1. In someembodiments, less or more phases or different orders of phases arecontemplated. Depending on the desired configuration, one or morecontroller(s) 790 may be used to control one or more various phases(e.g., various systems/devices therein) of the manufacturing process710. In some embodiments, one device/system may encompass multiplephases, such as two or more of the printing phase 730, the reel editorphase 740, the sheet formation/processing phase 760, and the finishingphase 770.

In some embodiments, like the manufacturing process 10 described withrespect to FIG. 1, the example folded carton manufacturing process 710may include one or more cutting devices 765 for cutting one or moresheets (or structures) from the roll of web product. Additionally, insome embodiments, a web forming device may form an updated web, such asprior to processing through the cutting device.

In some embodiments, the folded carton manufacturing process 710 mayinclude one or more unique devices, such as a folding/gluing device 775that may form part of the finishing phase 770 (or the sheetformation/processing phase 760). The folding/gluing device 775, such asusing one or more folding arms or other hardware and/or varioussoftware, may be configured to perform one or more folds of varioussheets to form the desired folded carton. In some embodiments, thefolding device 775 may be configured to apply glue separately or inaddition to performing the one or more folds.

FIG. 21 shows a block diagram of an example industrial bag manufacturingprocess. The manufacturing process 810 includes a number of phases thatresult in a finished industrial bag that is shaped, formed, and printedper the customer's order. The process 810 may include an ordering phase812, a planning phase 814, a print phase 830, a reel editor phase 840, asheet formation/processing phase 860, a finishing phase 870, and atracking/logistics phase 880. Such phases may be similar to the phasesdescribed with respect to the manufacturing phase 10 of FIG. 1. In someembodiments, less or more phases or different orders of phases arecontemplated. Depending on the desired configuration, one or morecontroller(s) 890 may be used to control one or more various phases(e.g., various systems/devices therein) of the manufacturing process810. In some embodiments, one device/system may encompass multiplephases, such as two or more of the printing phase 830, the reel editorphase 840, the sheet formation/processing phase 860, and the finishingphase 870. For example, an industrial bag manufacturing machine 850 mayencompass both the sheet formation/processing phase 860 and thefinishing phase 870.

In some embodiments, like the manufacturing process 10 described withrespect to FIG. 1, the example industrial bag manufacturing process 810may include one or more cutting devices 865 for cutting one or moresheets (or structures) from the roll of web product. Additionally, insome embodiments, a web forming device may form an updated web, such asprior to processing through the cutting device.

In some embodiments, the industrial bag manufacturing process 810 mayinclude one or more unique devices, such as a tuber device 872 and/orbottom device 874 that may form part of the finishing phase 870 (or thesheet formation/processing phase 860). The tuber device 872, such asusing various hardware and/or software, may be configured to form one ormore sheets into one or more tubes. The bottom device 874, such as usingvarious hardware and/or software, may be configured to form a bottom oneach of the tubes to form the industrial bag.

FIG. 22 shows a block diagram of an example cup manufacturing process.The manufacturing process 910 includes a number of phases that result ina finished cup that is shaped, formed, and printed per the customer'sorder. The process 910 may include an ordering phase 912, a planningphase 914, a print phase 930, a reel editor phase 940, a sheetformation/processing phase 960, a finishing phase 970, and atracking/logistics phase 980. Such phases may be similar to the phasesdescribed with respect to the manufacturing phase 10 of FIG. 1. In someembodiments, less or more phases or different orders of phases arecontemplated. Depending on the desired configuration, one or morecontroller(s) 990 may be used to control one or more various phases(e.g., various systems/devices therein) of the manufacturing process910. In some embodiments, one device/system may encompass multiplephases, such as two or more of the printing phase 930, the reel editorphase 940, the sheet formation/processing phase 960, and the finishingphase 970. For example, a cup manufacturing machine 950 may encompassboth the sheet formation/processing phase 960 and the finishing phase970.

In some embodiments, like the manufacturing process 10 described withrespect to FIG. 1, the example cup manufacturing process 910 may includeone or more cutting devices 965 for cutting one or more sheets (orstructures) from the roll of web product. Additionally, in someembodiments, a web forming device may form an updated web, such as priorto processing through the cutting device.

In some embodiments, the cup manufacturing process 910 may include oneor more unique devices, such as a cup former 977 that may form part ofthe finishing phase 970 (or the sheet formation/processing phase 960).The cup former 977, such as using various hardware and/or software, maybe configured to form one or more sheets (or structures) into a cup witha desired shape (e.g., the cup former 977 may employ a die-cutter thatcuts the sheet into a desired shape and a cup formation device thatforms the cylindrical cup shape with a bottom and glues the cuptogether).

FIG. 23 shows a block diagram of an example paper plate manufacturingprocess. The manufacturing process 1010 includes a number of phases thatresult in a finished paper plate that is shaped, formed, and printed perthe customer's order. The process 1010 may include an ordering phase1012, a planning phase 1014, a print phase 1030, a reel editor phase1040, a sheet formation/processing phase 1060, a finishing phase 1070,and a tracking/logistics phase 1080. Such phases may be similar to thephases described with respect to the manufacturing phase 10 of FIG. 1.In some embodiments, less or more phases or different orders of phasesare contemplated. Depending on the desired configuration, one or morecontroller(s) 1090 may be used to control one or more various phases(e.g., various systems/devices therein) of the manufacturing process1010. In some embodiments, one device/system may encompass multiplephases, such as two or more of the printing phase 1030, the reel editorphase 1040, the sheet formation/processing phase 1060, and the finishingphase 1070. For example, a plate manufacturing machine 1050 mayencompass both the sheet formation/processing phase 1060 and thefinishing phase 1070.

In some embodiments, like the manufacturing process 10 described withrespect to FIG. 1, the example paper plate manufacturing process 1010may include one or more cutting devices 1065 for cutting one or moresheets (or structures) from the roll of web product. Additionally, insome embodiments, a web forming device may form an updated web, such asprior to processing through the cutting device.

In some embodiments, the paper plate manufacturing process 1010 mayinclude one or more unique devices, such as a plate former 1078 that mayform part of the finishing phase 1070 (or the sheet formation/processingphase 1060). The plate former 1078, such as using various hardwareand/or software, may be configured to form one or more sheets (orstructures) into a plate with a desired shape (e.g., the plate former1078 may have a stamping device that stamps the sheet into a desiredshape).

Although the above description notes one or more distinctions betweenthe various manufacturing processes 710, 810, 910, 1010 and themanufacturing process 10, other distinctions are contemplated by someembodiments of the present invention. For example, thetracking/logistics phase for each manufacturing process may be differentor employ different techniques that allow for efficient manufacturing ofthe end product. Whether the same or different, varioustracking/marking/detecting techniques described herein may be employedwith manufacturing of such example products to provide for an efficientmanufacturing process.

Example Flowchart(s)

Embodiments of the present invention provide methods, apparatuses andcomputer program products for generating a control plan for a roll ofweb product for a manufacturing process according to various embodimentsdescribed herein. Various examples of the operations performed inaccordance with embodiments of the present invention will now beprovided with reference to FIG. 24.

FIG. 24 illustrates a flowchart according to an example method forgenerating a control plan for a roll of web product for a manufacturingprocess according to an example embodiment. The operations illustratedin and described with respect to FIG. 24 may, for example, be performedby, with the assistance of, and/or under the control of one or more ofthe controller 90, 590, 790, 890, 990, 1090 components of the phases inthe described manufacturing processes 10, 510, 710, 810, 910, 1010and/or modules present in the described platform 100.

The method 1100 may include receiving one or more orders at operation1102. At operation 1104, the method comprises gathering orderinformation from one or more discrete systems, such as a managementinformation system and a graphics planning system. Then, at operation1106, the method comprises receiving a request to generate a controlplan for a roll of web product. At operation 1108, the method includesproviding one or more available orders for selection and inclusion inthe control plan. At operation 1110, the method includes receiving atleast one selection of an available order to include in the controlplan. At operation 1112, the method includes adding the selected orderto the control plan. At operation 1114, the method includes calculatingan amount of waste for the currently proposed control plan. At operation1116, the method comprises generating the control plan for use duringthe manufacturing process.

FIG. 24 illustrates a flowchart of a system, method, and computerprogram product according to various example embodiments describedherein. It will be understood that each block of the flowcharts, andcombinations of blocks in the flowcharts, may be implemented by variousmeans, such as hardware and/or a computer program product comprising oneor more computer-readable mediums having computer readable programinstructions stored thereon. For example, one or more of the proceduresdescribed herein may be embodied by computer program instructions of acomputer program product. In this regard, the computer programproduct(s) which embody the procedures described herein may be storedby, for example, the memory and executed by, for example, the controller90. As will be appreciated, any such computer program product may beloaded onto a computer or other programmable apparatus to produce amachine, such that the computer program product including theinstructions which execute on the computer or other programmableapparatus creates means for implementing the functions specified in theflowchart block(s). Further, the computer program product may compriseone or more non-transitory computer-readable mediums on which thecomputer program instructions may be stored such that the one or morecomputer-readable memories can direct a computer or other programmabledevice to cause a series of operations to be performed on the computeror other programmable apparatus to produce a computer-implementedprocess such that the instructions which execute on the computer orother programmable apparatus implement the functions specified in theflowchart block(s).

CONCLUSION

Many modifications and other embodiments of the inventions set forthherein may come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the embodiments of the invention are not to belimited to the specific embodiments disclosed and that modifications andother embodiments are intended to be included within the scope of theinvention. Moreover, although the foregoing descriptions and theassociated drawings describe example embodiments in the context ofcertain example combinations of elements and/or functions, it should beappreciated that different combinations of elements and/or functions maybe provided by alternative embodiments without departing from the scopeof the invention. In this regard, for example, different combinations ofelements and/or functions than those explicitly described above are alsocontemplated within the scope of the invention. Although specific termsare employed herein, they are used in a generic and descriptive senseonly and not for purposes of limitation.

1. A system for generating a control plan for controlling manufacturingof one or more paper-based products, the system comprising: at least onecontroller configured to: receive a request for generation of a controlplan associated with a roll of web product for manufacturing one or morepaper-based products, wherein the request includes at least one criteriaregarding orders for the one or more paper-based products; provide aplurality of available orders for paper-based products for selection,wherein each of the plurality of available orders for selection satisfythe at least one criteria from the request and are associated with orderinformation, wherein the order information for each order comprisesinformation related to completing manufacturing of a desired productassociated with the order, wherein the order information is gatheredfrom a plurality of discrete systems; receive a selection of an orderfrom the plurality of available orders; and generate the control planassociated with the roll of web product, wherein the control planincludes at least the selected order.
 2. The system of claim 1, whereinthe at least one criteria for the request for generation of the controlplan is at least one of an indication of a desired width of the roll ofweb product or an indication of an available printer for use duringmanufacturing, wherein the printer is configured to process a maximumwidth for the roll of web product, wherein each of the plurality ofavailable orders for selection are able to fit within either the desiredwidth or the maximum width depending on the indicated criteria with therequest.
 3. The system of claim 1, wherein the at least one criteria forthe request for generation of the control plan is at least one of anindication of a desired job type characteristic, order number, orcustomer.
 4. The system of claim 1, wherein the plurality of discretesystems includes at least a graphics planning system and a managementinformation system, wherein the graphics planning system comprises orderinformation related to one or more desired images for the order, andwherein the management information system comprises order informationrelated to at least an amount of desired product for the order.
 5. Thesystem of claim 1, wherein the at least one controller is configured toprovide a ready status for each of the plurality of available orders forselection, wherein the ready status indicates that the order is readyfor proceeding with immediate manufacturing in an instance in which atleast order information for the order related to printing and sheetformation/processing has been gathered.
 6. The system of claim 1,wherein the at least one controller is configured to filter a databaseof aggregated available orders based on the at least one criteria fromthe request to determine the plurality of available orders to providefor selection.
 7. The system of claim 1, wherein the at least onecontroller is configured to determine an amount of waste on the roll ofweb product based on one or more selected orders and provide anindication of the amount of waste.
 8. The system of claim 7, wherein theat least one controller is configured to determine if the amount ofwaste satisfies an acceptable waste threshold and provide an indicationas to whether the amount of waste satisfies the acceptable wastethreshold.
 9. The system of claim 7, wherein the at least one controlleris configured to determine if the amount of waste satisfies anacceptable waste threshold and prevent generation of the control plan inan instance in which the amount of waste does not satisfy the acceptablewaste threshold.
 10. The system of claim 1, wherein the selected orderis a first order, and wherein the at least one controller is configuredto, in response to receiving the selection of the first order: determinea remaining width of the roll of web product that is available for oneor more orders; and provide a second plurality of available orders forselection, wherein each of the second plurality of available orders forselection are able to fit within the remaining width on the roll of webproduct.
 11. The system of claim 10, wherein the at least one controlleris configured to provide an indication of one or more recommended ordersfrom the second plurality of available orders for selection, wherein theone or more recommended orders are determined based on one or morefactors associated with the first order, wherein the one or more factorsassociated with the first order include at least one of deadlines,customers, color profiles, and manufacturing locations.
 12. The systemof claim 10, wherein the at least one controller is configured todetermine that an available sheet formation/processing system plannedfor use with the roll of web product that can accommodate a plurality oflanes prior to providing the second plurality of available orders forselection.
 13. The system of claim 10, wherein the at least onecontroller is configured to receive input indicating a desire to splitthe selected first order into two or more ribbons for the control plan.14. The system of claim 10, wherein the at least one controller isconfigured to: receive a selection of at least one second order; andprovide an optimization up or down function for enabling the overallnumber of sheet or box structures for at least one of the selected firstorder or the selected second order to be reduced or increased in orderto cause an overall length of the roll of web product being used for theselected first order to better align with an overall length of the rollof web product being used for the selected second order.
 15. The systemof claim 14, wherein the at least one controller is configured toprovide a recommendation for optimization up or down based on a customerassociated with at least one of the selected first order or the selectedsecond order being willing to receive extra sheet or box structures. 16.The system of claim 1, wherein the at least one controller is configuredto, in response to receiving a selection of an order, provide asuggested width for the roll of web product to minimize a remainingunused width of the roll of web product that is available afterincluding the selected order.
 17. The system of claim 1, wherein the atleast one controller is configured to provide an indication of one ormore recommended orders from the plurality of available orders forselection, wherein the one or more recommended orders are determinedbased on one or more factors, wherein the one or more factors include atleast one of upcoming deadlines, customers, and manufacturing locations.18. The system of claim 1, wherein the selected order includes orderinformation corresponding to a total number of desired sheet or boxstructures and a desired layout for a processing set of sheet or boxstructures, wherein each processing set of sheet or box structuresincludes a plurality of sheet or box structures that are positionedrelative to each other to form the processing set of sheet or boxstructures, wherein the at least one controller is configured todetermine, based on the selected order, a number of sets of sheet or boxstructures to apply to the control plan to satisfy the total number ofdesired sheet or box structures for the selected order.
 19. The systemof claim 1, wherein the at least one controller is configured todetermine a size of a web weave to apply to each width end of the rollof web product for the control plan.
 20. The system of claim 1, whereinthe at least one controller is configured to present a visualrepresentation of the roll of web product with the at least one selectedorder applied.
 21. The system of claim 1, wherein the at least onecontroller is configured to provide a preview of the roll of web productafter printing.
 22. The system of claim 1, wherein the at least onecontroller is configured to generate a label based on the control plan,wherein the label is configured to be applied to the roll of webproduct.
 23. The system of claim 22, wherein the label includes at leastone computer readable marking that, upon being read, at least one ofidentifies the control plan or supplies the control plan.
 24. The systemof claim 1, wherein the at least one controller is configured to form aset of printing instructions to enable operation of the printeraccording to the control plan, wherein the set of printing instructionsare formed into a format that is acceptable to the printer.
 25. Thesystem of claim 24, wherein the set of printing instructions includeinstructions regarding a color profile needed by the printer to printdesired images for the control plan.
 26. The system of claim 24, whereinthe set of printing instructions include instructions that cause theprinter to perform one or more test jobs prior to beginning a productionrun.
 27. The system of claim 24, wherein the set of printinginstructions include instructions that cause the printer to prepare oneor more golden images for use during one or more quality checks.
 28. Thesystem of claim 27, wherein the set of printing instructions includeinstructions that cause the printer to prepare the one or more goldenimages during a separate golden image processing run.
 29. The system ofclaim 27, wherein the set of printing instructions include instructionsthat cause the printer to prepare the one or more golden images duringthe production run at a specific position within an order on the controlplan.
 30. The system of claim 1, wherein the at least one controller isconfigured to form a golden image file that includes one or more goldenimages for use during one or more quality checks for at least theselected order for the control plan.
 31. The system of claim 30, whereinthe at least one controller is configured to provide the golden imagefile to a vision system that performs the one or more quality checks.32. The system of claim 30, wherein the at least one controller isconfigured to enable access to the golden image file by a vision systemthat performs the one or more quality checks.
 33. The system of claim30, wherein the golden image file includes at least one tolerance levelassociated with the one or more golden images for use by a vision systemthat performs the one or more quality checks to determine if the checkedimage is acceptable.
 34. The system of claim 1, wherein the at least onecontroller is configured to form a set of quality check instructions toenable a vision system to perform one or more quality checks, whereinthe set of quality check instructions provides access to one or moregolden images for use during the one or more quality checks for at leastthe selected order for the control plan.
 35. The system of claim 34,wherein the set of quality check instructions includes a separate goldenimage for performing a quality check on each lane of a multi-laneprinting press.
 36. The system of claim 34, wherein the set of qualitycheck instructions includes a single golden image that is used forperforming a quality check on a plurality of lanes of a multi-laneprinting press.
 37. The system of claim 1, wherein the at least onecontroller is configured to form a set of sheet formation/processinginstructions to enable operation of the sheet formation/processingsystem according to the control plan, wherein the set of sheetformation/processing instructions are formed into a format that isacceptable to the sheet formation/processing system.
 38. The system ofclaim 1, wherein the at least one controller is configured to track thestatus of the control plan during the manufacturing process.
 39. Agraphical user interface for generating a control plan for controllingmanufacturing of one or more paper-based products, the graphical userinterface being configured to: receive a request for generation of acontrol plan associated with a roll of web product for manufacturing oneor more paper-based products, wherein the request includes at least onecriteria regarding orders for the one or more paper-based products;provide a plurality of available orders for paper-based products forselection, wherein each of the plurality of available orders forselection satisfy the at least one criteria from the request and areassociated with order information, wherein the order information foreach order comprises information related to completing manufacturing ofa desired product associated with the order, wherein the orderinformation was gathered from a plurality of discrete systems; receive aselection of an order from the plurality of available orders; andgenerate the control plan associated with the roll of web product,wherein the control plan includes at least the selected order.
 40. Amethod for generating a control plan for controlling manufacturing ofone or more paper-based products, the method comprising: receiving arequest for generation of a control plan associated with a roll of webproduct for manufacturing one or more paper-based products, wherein therequest includes at least one criteria regarding orders for the one ormore paper-based products; providing a plurality of available orders forpaper-based products for selection, wherein each of the plurality ofavailable orders for selection satisfy the at least one criteria fromthe request and are associated with order information, wherein the orderinformation for each order comprises information related to completingmanufacturing of a desired product associated with the order, whereinthe order information is gathered from a plurality of discrete systems;receiving a selection of an order from the plurality of availableorders; and generating the control plan associated with the roll of webproduct, wherein the control plan includes at least the selected order.